di350 officeright inserting system operator guide … bowes di350 user manual.pdf · usefulness of...

Inserting SystemDI350 OfficeRightTM

Operator Guide

SV40190-OG Rev. A

Contents

ii

First Edition, September 2002©2002 Pitney Bowes Inc.All rights reserved. This book may not be reproduced in whole or in partin any fashion or stored in a retrieval system of any type or transmittedby any means, electronically or mechanically, without the expresswritten permission of Pitney Bowes.

We have made every reasonable effort to assure the accuracy andusefulness of this manual, however we cannot assume responsibilityfor errors or omissions or liability for the misuse or misapplication of ourproducts.

NOTE: This equipment has been tested and found tocomply with the limits for a Class A device, pursuant to part15 of the FCC rules. These limits are designed to providereasonable protection against interference when theequipment is operated in a commercial environment. Thisequipment generates, uses and can radiate radio fre-quency energy, and if not installed and used in accordancewith the instruction manual, may cause interference toradio communications. Operation of this equipment in aresidential area is likely to cause interference, in whichcase the user, at their own expense, will be required tocorrect the interference.

Trademark NoticeOfficeRight™ and EZ Seal® are trademarks of Pitney Bowes Inc.

Contents

iii

ABOUT THIS GUIDE

This guide explains how to setup and use the DI350OfficeRight™ Inserting System . Please spend a fewmoments reading through it. Understanding what the inserterdoes, and how it does it, will keep problems to a minimumand help you get the best performance possible.

This Guide is organized into seven sections:

1. INTRODUCTION

To the Operator 1-5Three-Station Model .................................................... 1-5Two-Station Model ...................................................... 1-6One-Station Model ...................................................... 1-6

Safety ................................................................................ 1-7Machine Identification ....................................................... 1-8Control Panel .................................................................. 1-10

Control Panel Buttons ............................................... 1-10Display Symbols ........................................................ 1-12

2. OPERATION

Connecting Power ............................................................. 2-1Selecting and Running a Job ............................................ 2-1

Select the Job.............................................................. 2-1Run a Trial Piece ......................................................... 2-2Start Machine Operation ............................................. 2-3

Setting the Sheet Feeders ................................................ 2-3Setting the Envelope Feeder ............................................. 2-4Setting the Insert Feeder ................................................... 2-5Filling the Sealer ............................................................... 2-6Programming Options By Model ....................................... 2-7

Contents

iv

3. CREATE A NEW NON-OMR JOB

Create New Non-OMR Job ............................................... 3-1Entering the Setup Mode............................................. 3-1Choosing the New Job Number .................................. 3-2Selecting Non-OMR Option ......................................... 3-2Flowchart for Non-OMR Job........................................ 3-3Setting the Accumulation Function .............................. 3-5Fold Type .................................................................... 3-6Setting Sheet Feeder 1 ............................................... 3-7Setting Sheet Feeder 2 ............................................... 3-8Setting Insert Feeder ................................................... 3-9Mode ........................................................................... 3-9Sealer ........................................................................ 3-10Paper Length ............................................................. 3-10Fold A ........................................................................ 3-11Fold B ........................................................................ 3-11Envelope Depth ......................................................... 3-12Envelope Stop ........................................................... 3-12Batch Mode ............................................................... 3-13Confirming the Job Setup .......................................... 3-13Testing the Job .......................................................... 3-14

Changing an Existing Job ............................................... 3-15Deleting a Job ................................................................. 3-15

Contents

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4. WHAT IS OMR (OPTICAL MARKRECOGNITION)?

What is OMR? ................................................................... 4-1What Do OMR Marks Look Like on Paper? ...................... 4-2How are OMR Marks Read on the DI350? ....................... 4-3How are OMR Marks Generated? ..................................... 4-4What OMR Marks are Used on the DI350? ...................... 4-5OMR Group Combinations ................................................ 4-9Details of Basic Level OMR ............................................ 4-10 Group 1 Marks (“OMR”) ............................................. 4-10Details of Enhanced Level OMR ..................................... 4-14 Group 2 Marks (“Select Feed”) ................................... 4-14 Group 3 Marks (“Sequence”) ...................................... 4-17Considerations When Implementing OMR ...................... 4-20

Contents

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5. CREATE A NEW OMR JOB

Creating a New OMR job .................................................. 5-1What Is OMR? ............................................................. 5-1Entering the Setup Mode............................................. 5-1Choosing the New Job Number .................................. 5-2Selecting OMR Option ................................................. 5-3Flowchart for OMR Job ............................................... 5-4Fold Type .................................................................... 5-6Setting Main (Scanning) Sheet Feeder ....................... 5-7Setting Other Sheet Feeder ........................................ 5-7Setting Insert Feeder ................................................... 5-9Sealer ........................................................................ 5-10Paper Length ............................................................. 5-10Fold A ........................................................................ 5-11Fold B ........................................................................ 5-11Envelope Depth ......................................................... 5-12Envelope Stop ........................................................... 5-12Batch Mode ............................................................... 5-13Confirming the Job Setup .......................................... 5-13Adjustment of OMR Scanner ..................................... 5-14Loading the Material .................................................. 5-17Testing the Job .......................................................... 5-18

Changing an Existing Job ............................................... 5-19Deleting a job .................................................................. 5-19

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6. REFERENCE

Changing the Display Language ....................................... 6-1Clearing Material ............................................................... 6-1

Hand Crank ................................................................. 6-1Removal & Replacement of Sheet Feeder and Envelope Trays ........................................................ 6-2Removal & Replacement of the Fold Plates ................ 6-2Removal & Replacement of the Insert Tray ................ 6-3Access to Carriage Assembly ..................................... 6-3Access to Envelope Feeder Area ................................ 6-3Access to the Envelope Exit Area ............................... 6-4Access to the Envelope Inserting Area ....................... 6-4Access to the Sheet Feed Area................................... 6-4

Troubleshooting ................................................................ 6-5Error Messages ............................................................... 6-11

Paper Handling.......................................................... 6-11OMR Errors ............................................................... 6-15

Material Specifications .................................................... 6-17Sheet Feeders ........................................................... 6-17Insert Feeder ............................................................. 6-17Sealer ........................................................................ 6-18Stacker ...................................................................... 6-18Envelope Feeder ....................................................... 6-18Material Requirements .............................................. 6-19

OMR Specifications (General) ........................................ 6-19Machine Specifications ................................................... 6-20

Physical Dimensions: ................................................ 6-20Noise Level ................................................................ 6-20Electrical/BTU Rating ................................................ 6-20Speed ........................................................................ 6-20Fold Modes ................................................................ 6-20Compliance ............................................................... 6-20Usage ........................................................................ 6-21Machine Life .............................................................. 6-21

Service ............................................................................ 6-21

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APPENDIX A – TRAINING CHECKLIST

Operator Training Checklist ..............................................A-1Introduction ..................................................................A-1Operation.....................................................................A-1Create (Program) Non-OMR Job ................................A-1What Is OMR? .............................................................A-2Create (Program) OMR Job ........................................A-2Reference ....................................................................A-2

INDEX

1-1

Introduction1. INTRODUCTION

To the Operator

Your Pitney Bowes DI350 Inserting System is a compact,desk top unit, which is simple to set up and run while offeringthe following features:

• Envelope seal/no seal option• Semi-automatic single insert operation (not on single station model)• Fully automatic material separation on sheet feeder(s)• Fully automatic settings on fold plates• Fully automatic envelope separation• Fully automatic double document detection when selected• Fold only option (fold without insertion)• Semi-automatic insertion of single and multiple sheet Inserts• Option of single fold, letter (C) fold, accordion (Z) fold or double fold• Job recall, operator programmable (up to 20, depending on model)• Switchable feeding• Optical Mark Recognition (OMR) scanning for greater collation

integrity and additional feeding flexibility (3-station model only)

This guide covers all three models of the DI350 inserter system.

Three-Station ModelThis model incorporates two sheet feeders and an insert feeder.It is the only model that has OMR and has the most setupoptions. For this reason, all illustrations in this guide show thismodel.

SheetFeeder 1 Insert Feeder

SheetFeeder 2

1-2

Introduction

Two-Station ModelThis model incorporates a single sheet feeder and an insertfeeder.

One-Station ModelThis model incorporates a single sheet feeder.

All models are set up and operated in a very similar way.Procedures in this guide cover all models. If a function ismodel dependent, the accompanying text will explain this.

Sheet Feeder 1

Insert Feeder

Sheet Feeder 1

1-3

Introduction

Safety Precautions:

When using this machine, follow the normal safety precautions for alloffice equipment:

Keep loose clothing, jewelry and long hair away from all moving parts.

Avoid touching moving parts or materials while the machine is in use.

Before clearing a jam, be sure machine mechanisms come to a stop.

When removing jammed material, avoid using too much force toprotect against minor personal injury and damaging equipment.

Use the power cord supplied with the machine and plug it into aproperly grounded wall outlet located near the machine and easilyaccessible. Failure to properly ground the machine can result in severepersonal injury and/or fire.

The power cord wall plug is the primary means of disconnecting themachine from AC supply.

DO NOT use an adapter plug on the line cord or wall outlet.

DO NOT remove the ground pin from the line cord.

Avoid using wall outlets that are controlled by wall switches, or sharedwith other equipment.

DO NOT route the power cord over sharp edges or trapped betweenfurniture.

Insure there is no strain on the power cord where it becomes jammedbetween the equipment, walls or furniture.

Be certain the area in front of the wall receptacle into which themachine is plugged is free from obstruction.

Do not remove covers. Covers enclose hazardous parts that shouldonly be accessed by Pitney Bowes Customer Service. Report anydamage of covers to a Pitney Bowes Customer Service Representative.

To prevent overheating, do not cover the vent openings.

Read all instructions before attempting to operate the equipment.

Use this equipment only for its intended purpose.

In addition, follow any specific occupational safety and healthstandards for your workplace or area.

Safety

1-4

Introduction

2

Machine Identification

1 6 11 3 4 10

9 8 7

5

1 Sheet Feeder 1This feeder is intended for feeding material that requiresfolding. If you are running addressed documents forinsertion into window envelopes, feed them from thisfeeder.

In addition, sheet feeder 1 can be set to ‘manual feed’. Inthis mode, stapled sets of up to 5 sheets may be run. Themachine waits for each set to be manually fed into sheetfeeder 1 before folding and inserting the set automatic-ally. See the specifications section of Chapter 6(Reference) for full details of the sets possible.

2 Sheet Feeder 2 (three-station machine only)For feeding material that requires folding. Its functionsare similar to sheet feeder 1 but ‘manual feed’ is NOTavailable from this feeder.

12

13

1-5

Introduction

3 Insert Feeder (two and three-station machines only)Use this feeder to add additional inserts to yourenvelope. Material fed from this feeder cannot be foldedby the inserter. However, this feeder is especially suitedto feeding pre-folded or thicker inserts.

4 Fold Plate 25 Fold Plate 1

These units are used to create the desired fold inmaterial fed from the sheet feeder(s). The fold plates areautomatically set from the control panel.

6 Display/Control PanelThis is where you enter commands and where themachine informs you of its status with the use of symbolsand icons. Full details of each button function are givenon the following page.

7 Stacker and Measuring ScaleLocated at the right end, is the fold-down stacker. Thisunit can be latched against the right side of the machinewhen not in use to save space.

A scale is located along the front edge of the stacker toaid measurement of material and envelopes.

8 Hand CrankThe hand crank is located behind a drop down cover atthe left front. It can be used to manually turn the machinemechanisms to free a material stoppage.

9 Envelope FeederThis feeder feeds envelopes into the inserting areawhere they are filled with the sheets requested from theother feeders.

10 Envelope Inverter UnitThis unit exits the envelope into the stacker face up.11

1-6

Introduction

11 Sealer Water BottleThe sealer water bottle is located behind a drop downcover at the right rear of the machine. It provides water orEZ Seal® solution to the envelope sealer unit.

12 Upper OMR Scanner (three-station machine only)Scanner used to read OMR marks on sheet feeder 1 fromabove the sheet.

13 Lower OMR Scanner (three-station machine only)Scanner used to read OMR marks on sheet feeder 2 fromunder sheet.

Control Panel

Control Panel ButtonsDefault Press this button to return the system to its

‘standard’ settings. These settings come pre-configured from the factory but can be modified tosuit your needs by a Pitney Bowes Customer ServiceRepresentative.

Job Press to step through the jobs you have programmedinto the machine’s memory. Up to twenty (20) jobs canbe held, depending on model (see page 2-9). SeeChapters 3 or 5 for details on programming jobs.

1-7

Introduction

Next

Reset Counter Press this button to reset the item counter.

Clear Deck Pressing this button will jog material through and outof the machine. It can be used to clear the machineready for automatic operation after a stoppage hasoccurred etc.

Trial Piece This button is used to run a single test piece so thatyou can check machine setup. A trial piece must berun before automatic operation can be commencedusing the Start button. If double detection is in use,the machine sets itself automatically as it runs thetrial piece. This envelope will be unsealed andcounted as one item.

Start Starts automatic operation.

Stop Stops automatic operation at the end of the nextcycle.

Delete Used in setup mode to delete a programmed jobfrom memory.

Setup When pressed, the machine enters setup mode. Thismode allows you to program jobs into memory forinstant recall using the Job button.

Change + – In setup mode, used to select options or set valuesof machine settings.

Prev. In setup mode, used to step backwards/forwardsthrough the various machine settings.

1-8

Introduction

Display Symbols

Used on sheet feeders tosignify that the feeder ison without doubledetection.

Used on sheet feeders tosignify that the feeder ison with double detection.

Used on insert feeder tosignify that the feeder is onwithout double detection.

Used on insert feeder tosignify that the feeder ison with double detection.

Used on sheet feeder 1 tosignify that the feeder isset for manual feed.

Used on envelope feederto signify that the feeder ison.

Indicates the setting (from1 to 5) of the envelopestop.

Indicates that the sealerwater bottle needs refilling.

Indicates the envelopedepth.

Indicates that the sealerunit is off (envelopes notsealed).

Used on any feeder toindicate feeder is not in use.

Indicates that the sealerunit is on (automaticenvelope sealing).

Indicates a ‘C’ - Letterfold is selected.

Indicates a ‘Z ’ -Accordion fold isselected.

Indicates a double foldis selected.

Indicates a single fold isselected.

Indicates a no-fold insertoperation.

Indicates a materialstoppage. The position ofthis symbol in the displayindicates where thestoppage has occurred.

Call Pitney BowesService.

Indicates the paper size,address orientation andfold(s) set for sheetfeeder.

. . 3 . .

Operation

2-1

2. OPERATION

This section explains operation of the DI350 inserter, assum-ing the job to be run is already programmed into the machine.

If the job has not been programmed, refer to “Create Non-OMR Job” on page 3-1 or “Create OMR Job” on page 5-1.

Connecting Power

Read the safetyinformation onpage 1-3 beforeconnecting themachine.

Connect the power cord tothe socket on the left side ofthe machine. Plug the powercord into a suitable poweroutlet. Make sure the power outlet is near the machine and iseasily accessible. Turn the machine power switch ON.

!

Select the JobWhen the machine is turnedON, the display will show thelast job run and ‘Trial PieceRequired’.

Press the Job button until thejob you require is displayed,or press Default if you want to run the machine with your‘standard’ settings.

Note: The default job can be altered only by a Pitney BowesCustomer Service Representative.

Selecting and Running a Job

Operation

2-2

If you have material loaded,press Trial Piece. Themachine will set itself andrun a test piece for you tocheck.

If you don’t have material loaded, do this now, then return tothis section. Loading feeders etc. is covered on the followingpages.

Note:You may have selected a‘manual feed’ job wheresheet feeder 1 is set formanual feed of collated sets.If this is the case, the sheetfeeder should not be loaded,as the collated sets are fedone at a time as required bythe machine. However, thelever shown in the illustration should be pulled back to openthe feed mechanism to ready the manual feed operation.Remember to return this lever to its normal position whenyou use the feeder for automatic operation.

Run a Trial Piece

Once material is in place, press Trial Piece so you cancheck that the setup is correct.

Note: In switchable mode both sheet feeders must be loaded. Atrial piece will be run for both feeders.

Minor changes to the job settings can be made at this stageif the trial piece needs ‘fine tuning’. Press Setup, then usethe Prev ( ), Next ( ) and Change (+/-) buttons asrequired to modify job settings. When you have made thenecessary changes, press Setup again to return to runmode. The job will be saved with the new settings.

Operation

2-3

Start Machine Operation

Press Start to begin automatic operation. The machine willoperate until either material runs out or the Stop button ispressed.

Note: If the three station machine is set for switchablefeeding, the display will show:

Ready: 1 > 2 > 1

This confirms that feeding will automatically switch betweensheet feeders. See page 3-8 or 5-7 for more details.

Setting the Sheet Feeders

1. Adjust the side guides tothe width of the materialbeing fed, then back-off aquarter turn on the sideguide control. This willset the correct clearancebetween the guides andthe material.

2. Take the stack of paperand aerate it to ensurethe individual sheets arenot stuck together.

Operation

2-4

3. Jog the stack back intoalignment. The sheetfeeders take the paperstack aligned in a similarway to a photocopierpaper cassette.

4. The three possiblechoices for loading you documents with addresses arelisted below. NOTE: The display will indicate the correctorientation of the paper in the first two cases only.

5. Place the paper stack ontothe feed deck. Allow thedeck to move down andthe top of the paper stackto slide under the feedroller.

Note: When using bothsheet feeders withaccordion fold, sheetfeeder 2 must be used forthe prime (address bearing)document.

6. You can pull out the sliding supports from the end of thedeck to help support long material.

FACE UPFEET FIRSTA

BCFACE DOWN

FEET FIRSTABC

FACE UPHEAD FIRST

AB

C

Operation

2-5

Setting the Envelope Feeder

1. Adjust the side guidesto the width of theenvelopes being fed,then back-off half aturn on the side guidecontrol. This will setthe correct clearancebetween the guidesand the envelopes.

2. Aerate the stack ofenvelopes to be run.

3. Place them on the feeddeck with the flaps upand trailing. The leadedge of the firstenvelope should beunder the front feedroller.

Let the ‘wedge’ slidedown behind the stack sothat the envelopes aresupported.

Operation

2-6

Setting the Insert Feeder

1. Adjust the side guides tothe width of the materialbeing fed, then back-off aquarter turn on the sideguide control. This willset the correct clearancebetween the guides andthe material.

2. Refer to the ‘label’located on the insertfeeder. Compare your insert with the diagram. Read offthe settings for the insert feeder blue lever (numbers 1 to9) and the separator shield (letters A to D).

3. Set the blue lever to thenumber required.

Thin Material

Thicker MaterialThick Inserts/Booklets etc.

Operation

2-7

4. Set the separator shieldto the letter required.

5. Fan the inserts to be runand place them onto thefeed deck face up withtheir bottom edge feedingfirst.

Let the ‘wedge’ slidedown behind the stack sothat the inserts aresupported.

Operation

2-8

Fill the bottle up to the level indicated.

Replace the water bottle and close the cover.

If the sealer unit has been allowed to completely empty, youshould allow time for water to soak through the sealermechanism.

Filling the Sealer

When the sealer unit needs refilling, the Add Fluid symbolwill flash in the display.

Add Pitney Bowes EZ Seal®solution or water in thefollowing way:

Note: EZ Seal® solution isrecommended to minimizegrowth of algae and scalebuild-up.

Hinge open the Water BottleCover located at the rear right hand side of the machine.Remove the bottle

Operation

2-9

Programming Options By Model

The DI350 has the ability to be programmed by the operatorwith up to 20 jobs (depending on model) which can be recalledat the touch of a button. The following table shows whichfunctions are available on a machine by the number of stationsit has (✓ = present on machine):

Sheet Feeder 1 ✓ ✓ ✓ On (with double detect), On (withoutdouble detect), Off, or Manual Feed

✓ In addition to above: Select Feed (withdouble detect), or Select Feed (withoutdouble detect)

Insert Feeder ✓ ✓ On (with double detect), On (withoutdouble detect), Off

✓ In addition to above: Select Feed (withdouble detect), or Select Feed (withoutdouble detect)

Sheet Feeder 2 ✓ On (with double detect), On (withoutdouble detect), Off, Select Feed (withdouble detect), or Select Feed (withoutdouble detect)

Accumul Mode ✓ ✓ ✓ Off or On (with 2, 3,4, or 5 pages)

OMR Mode ✓ Off, On, OMR + Sequence, OMR +Select Feed and Sequence, OMR +Select Feed

Mode ✓ ✓ ✓ Insertion Mode, Fold Only Mode

Number of Jobs 10 10 20 Each job can be programmed by operator

Fold Type ✓ ✓ ✓ C - Letter, Z - Accordion, Double orSingle

Paper Length ✓ ✓ ✓ any within machine specification limits

Fold A ✓ ✓ ✓ any within machine/fold specificationlimits

Fold B ✓ ✓ ✓ any within machine/fold specificationlimits

Envelope Depth ✓ ✓ ✓ any within machine specification limits

Envelope Stop ✓ ✓ ✓ 1 to 5

Batch Mode ✓ ✓ ✓ Off or On (from 50 to 99)

Possible SettingsFunction# of Stations 1 2 3

Operation

2-10

Create Non-OMR Job

3-1

3. CREATE NON-OMR JOB

This section takes you step-by-step through the process ofsetting up a new (non-OMR) job and saving it in the memory.

Programming is carried out in the ‘Setup Mode’…

Entering the Setup ModeOpen the hinged cover to the right of the display. This willexpose the setup buttons.

Press Setup. The indicator will light and the machine will askfor an access code. This code prevents the machine’ssettings being changed by unauthorized personnel.

The Prev ( ) and Next ( )buttons are used to stepforward or backwards throughthe settings available. Oncethe item is displayed, theChange (+/-) buttons areused to select the option orvalue you want.

Use the Change (+/-) buttonsto select the access code 71.

Press Next ( ) to advanceto the next setting….

Create Non-OMR Job

3-2

Choosing the new job numberThe machine will ask for thejob number you wish the newsettings to be stored under(the default job number is 1).Use the Change (+/-) buttonsto display the job number you want.

Notes:• If you use an existing job

number, the old settingswill be overwritten by thenew settings you areabout to make.

• If you want to find acurrently unused job number, press Change (+/-)until yousee a job where the display shows no symbols alongsidethe feeders or in the fold setup area. This means the jobis currently empty.

Press Next ( ) to advance to the next setting…

Selecting Non-OMR OptionPress Change (+/-) until you see this option:

OMR off OMR is turned off for this job.

Press Next ( ) to advance to the next setting... (see page 3-5)

The flowchart on the following pages describe the setup for anon-OMR job.

Create Non-OMR Job

3-3

Open hinged cover on right side of control panel and press Setup key

Use + / - keys to enter 7 1 for access code, then press > key

Use + / - keys to enter job number, then press > key

Use + / - keys to select OMR function, then press > key

Use + / - keys to select whether the main sheet feeder is:• On Double Detect• Manual Feed• On• Off• Switchable - On Double Detect• Switchable - On then press > key

OMR off OMR onOMR +

SequenceOMR + Select

Feed + SequenceOMR + Select

Feed

Base Level Enhanced

Use + / - keys to select accumulation Off or On, then press > key

Use + / - enter keys to select 2, 3, 4 or 5 pages,

then press > key

Use + / - keys to select fold type (c-letter, z-accordion, double, single),

then press > key

Level Only

See Separate Flowchart for

OMR Job

OnOf f

Flowchart for Non-OMR Job Setup

continued on next page

Create Non-OMR Job

3-4

Flowchart for Non-OMR Job Setupcontinued from previous page


Use +/ - keys to select whether other sheet feeder is Off, On with

double detect or On with no double detect, then press > key

Use + /- keys to select whether insert feeder is Off, On with


Use +/ - keys to select whether sealer is Off or On, then press > key

Use +/ - keys to change paper length of your sheets, then press > key

Use + /- keys to change Fold A setting (if neccesary), then press > key to

continue

Use + /- keys to change Fold B setting (if neccesary), then

press > key to continue

Use +/ - keys to change envelope depth, then press > key

C, Z, Double Folds

Use +/ - keys to select whether insert feeder is in insertion mode or fold only

mode, then press > key

Insert Feeder On

Single Fold

Insert Feeder Off

Create Non-OMR Job

3-5

Flowchart for Non-OMR Job Setup

continued from previous page

Setting the Accumulation FunctionPress Change (+/-) until you see the option you want:

Accumulation: OFFAccumulation is turned off forthis job.

Accumulation: ONAccumulation is turned on forthis job.

Accumulation = 2/3/4/5 Select how many pages you want tofeed into each envelope. Either 2, 3, 4 or 5 pages can beselected.


Use +/ - keys to change envelope stop setting, then press > key

Use +/ - keys to select whether batch mode is Off or On, then press > key

Use +/ - keys to enter batch counter (from 50 to 999),

then press > key

Job number displays (back at beginining)

Batch OnBatch Off

Create Non-OMR Job

3-6

C - Letter Folds your sheet into a standard ‘C’or letter fold.

Z - Accordion Folds your sheet into a ‘Z’ oraccordion fold.

Double Folds your sheet in half and then inhalf again.

Single Folds your sheet once.

When the fold type is set as required, press Next ( ) toadvance to the next setting…

Fold TypeSelect the type of fold.

Press Change (+/-)until you see the optionyou want:

Create Non-OMR Job

3-7

Setting Sheet Feeder 1 (Upper Feeder)Select whether you want to use sheet feeder 1 and, if so,how it will be used.

Press Change (+/-) until you see the option you want:

On Double Detect Feeder on with the doubledetector operating. (The doubledetector stops the machine ifmore than one sheetsimultaneously feeds from thefeeder).

On Feeder on without the doubledetector.

Manual Feed Allows you to manually feedcollated sets (see notes below).

Off Feeder turned off for this job.

Switchable: On These functions are available onlySwitchable: On Dble Detect on the three-station machine.

Feed will initially be from SheetFeeder 1. When the feeder isempty, the machine willautomatically switch to feedingfrom sheet feeder 2.

When a trial piece is requested,both feeders must be loaded as atrial piece will be fed from eachfeeder

Notes About Manual Feed:1. The manual feed setting allows stapled sets of up to 5 sheets

of 20/24 lb (to a maximum of 120 lbs per set) to be run. Themaximum compressed thickness of the set after folding mustnot exceed 2mm. The machine will wait for manual insertion ofeach set into sheet feeder 1 after which it will fold and insertthe set automatically.

2. When running manual feed mode, sheet feeder 2 becomesinoperable

Create Non-OMR Job

3-8

When sheet feeder 1 is set as required, press Next ( ) toadvance to the next setting…

Setting Sheet Feeder 2 (Lower Feeder)Select whether you want touse the sheet feeder 2. Thisfunction is available only onthe three-station model.

Press Change (+/-) until yousee the option you want:

On Double Detect Feeder on with the double detectoroperating. (The double detectorstops the machine if more thanone sheet simultaneously feedsfrom the feeder).



When sheet feeder 2 is set as required, press Next ( ) toadvance to the next setting…

Create Non-OMR Job

3-9

Setting Insert FeederSelect whether you want to use the insert feeder and, if so,how it will be used. This function is available only on the twoand three-station models.

Press Change (+/-) until you see the option you want:

On Double Detect Feeder on with the double detectoroperating. (The double detectorstops the machine if more thanone insert simultaneously feedsfrom the feeder).



When the insert feeder is set as required, press Next ( ) toadvance to the next setting…

ModeThis option only appears if you have the insert feeder turnedoff. In this case, the machine needs to know if the jobrequires inserting into an envelope or if it is a fold only job.

If the insert feeder has been set to ‘on’, the machineautomatically sets itself to Insertion Mode and advances tothe Sealer option on the next page.

If ‘Insertion Mode’ appears on the display, you must choosethe machine’s mode of operation. Press Change (+/-) toswitch between the options:

Insertion Mode Activates the Envelope Feeder for a normalinserting job.

Fold Only Mode Turns the Envelope Feeder off and makes themachine act as a folding machine.

When the mode is set as required, press Next ( ) to advanceto the next setting…

Create Non-OMR Job

3-10

Paper LengthSelect the paper length.

Use the scale on the edge ofthe stacker.

Quick reference: US Letter length 11" (279mm) A4 paper length 297mm

Press Change (+/-) until the length of your paper (inmillimeters) is displayed.

When the paper length is correct, press Next ( ) to advanceto the next setting…

SealerThis setting only appears if aninsertion mode has beenselected.

Select whether you want to sealenvelopes or not.

Press Change (+/-) to switch the option on or off:

On Turns the sealer unit on for automatic sealing ofenvelopes. Make sure the sealer water bottle is fullof EZ Seal® or water (see page 2-8).

Off Turns the sealer unit off. Envelopes will be ejectedunsealed.

When the sealer is set as required, press Next ( ) to advanceto the next setting…

If you have selected either of the sheet feeders, the nextsetting offered will be fold type. However, if you are using theinsert feeder only, folding is not possible and the machine willadvance directly to the envelope depth setting (page 3-12).

Create Non-OMR Job

3-11

Fold ASelect the size of the firstfold required.

Depending on the settingspreviously made for fold typeand paper length, the machine will be suggesting the correctdimension for the first fold. Most times, therefore, this settingwill not require alteration.

If you want to change the ‘standard’ setting, press Change(+/-) until the length of fold required is displayed. The symbol| –––– | shows the fold panelyou are adjusting.

The machine willautomatically limit yourchoices to what is physicallypossible within the machinespecifications. (As you change the length of fold A, you willsee the dimension of fold B automatically changing to keepwithin paper length and machine specifications.)

When the setting is correct, press Next ( ) to advance tothe next setting…

Fold BSelect the size of the secondfold required.

In a similar way to fold A, themachine will be suggestingthe correct dimension for thefold.

If you want to change the ‘standard’ setting, press Change(+/-) until the length of fold required is displayed. The symbol| –––– | shows the fold panel you are adjusting.

When the setting is correct, press Next ( ) to advance to thenext setting…

Create Non-OMR Job

3-12

If you are programming an inserting job the setting EnvelopeDepth will now appear. If you are programming a fold onlyjob, the display will jump straight to the ‘Confirming the JobSetup’ section on the next page.

Envelope DepthSelect the depth of your envelopes (in millimeters).

Again, you can use thescale on the stacker tomeasure the depth of yourenvelopes. Press Change(+/-) until the correctdimension is displayed.When the envelope depth isset as required, press Next ( ) to advance to the nextsetting…

Envelope StopSelect the position of the machine’s envelope stop.

The stop has five positionsnumbered 1 to 5. Setting 3 isthe ‘standard’ setting fornormal weight paper withstandard folds. A thinner/lighter envelope will require alower setting and thicker/heavier envelope a higher setting.

Press Change (+/-) until the setting you want is displayed.

When the envelope stop is set as required, press Next ( ) toadvance to the next setting…

Create Non-OMR Job

3-13

Batch ModeThe batch mode allows you to automatically process pre-defined batches of finished mailpieces. The system “countsdown” from the number programmed for that job. When thebatch is complete (has reached “0”), the machine will stop,allowing you to empty the stacker. Pressing Start willcommence processing of the next batch.

If batch mode is not selected, the display counter will simplycount the number of items processed until reset by pressingReset Counter.

Press Change (+/-) to switchbatch mode On or Off.

When the setting is correct,press Next ( ).

If batch mode is turned On,the machine will now requestthe batch quantity. Thedefault quantity is 50, but youmay select any value up to999 using the Change (+/-) buttons.

When the setting is correct, press Next ( ).

Confirming the Job SetupJob setup is now complete.The display will show thecomplete job setup for you toconfirm. If you see a settingthat is incorrect, use the Prev( ) button to backtrack tothe setting and correct it.

When you are satisfied with the program, press the Setupbutton. The machine will save the job into its memory andreset to the new job.

Create Non-OMR Job

3-14

Testing the JobLoad material and press Trial Piece so that you can checkthat the setup is correct.

Minor changes to the job settings can be made at this stageif the trial piece needs ‘fine tuning’. Press Setup, then usethe Prev ( ), Next ( ) and Change (+/-) buttons asrequired to modify job settings. A chart is provided below tohelp ‘fine tune’ your fold settings.

FOLD TYPE ADDRESS TOO LOW ADDRESS TOO HIGH

“C” - Letter Fold Decrease Fold A Increase Fold A andincrease Fold B by thesame amount

“Z” - Accordion Increase Fold A Decrease Fold A and Fold increase Fold B

by the same amount

Single Fold Increase Fold A Decrease Fold A

Double Fold Decrease Fold A Increase Fold A

It is recommended that the folds are changed by 5mm eachtime and a new trial piece run to test the settings. When youhave made the necessary changes, press Setup again toreturn to run mode. The job will be saved with the newsettings.

When this is complete, thedisplay will show the new jobwith the message ‘Trial PieceRequired’.

Job settings will be retained by the machine even with powerdisconnected until they are changed or deleted as describedon the following page.

Create Non-OMR Job

3-15

Changing an existing job

To change an existing job…1. Enter the setup mode as described on page 3-1.

2. Use the Change (+/-) buttons to display the job you wishto edit.

3. Use the Prev ( ) and Next ( ) buttons to display thesetting(s) you wish to change.

4. Use the Change (+/-) buttons to change the options/dimensions you wish to amend.

5. Press the Setup button to leave setup mode and savethe changes.

Deleting a job

To erase an existing job from memory, follow the stepsbelow:1. Enter the setup mode as described on page 3-1.

2. Use the Change (+/-) buttons to display the job you wishto delete.

3. Press the Delete button. The display reads “Press againto confirm”. Press Delete again. The display will brieflyread ‘Deleting Job’ as the job is erased.

4. Press the Setup button to leave setup mode.

Create Non-OMR Job

3-16

What is OMR?

4-1

4. WHAT IS OMR?

DI350 inserters that are 3-station models have an OpticalMark Recognition (OMR) scanner installed on the upper andlower sheet feeders. This section describes what OMR is andhow it can be used to enhance your use of the machine foryour inserting needs. Once you understand the OMR con-cepts (and you have printed your documents with the properOMR marks), go to Chapter 5 for instructions on setting upan OMR job and adjusting the OMR scanners.

What is OMR (Optical Mark Recognition)?OMR (Optical Mark Recognition) is a system whereby marksare pre-printed on all pages that make up a document,statement, advertisement, etc. These pages are fed into themachine and their OMR marks “read” by the system, whosejob is to interpret the marks and do the prescribed tasksassociated with those marks (such as feeding sheets orverifying the end of a document).

The tracking of these OMR marks by the system assures thatsheets of a document which belong together (a collated set)actually stays together throughout the inserting process. Thisis known as collation set integrity. The more OMR marks thatare printed and read, the better the collated set integrity.However, more space and programming is required to printadditional marks on a document, so you will need to weighthe trade-off between more integrity and the space you haveavailable on your document.

The OMR mark itself is normally a dark solid line on a sheetof light-colored paper (usually white) that is horizontallypositioned so it matches the direction of travel of the paper.This line must be printed to certain specifications in width,length, and separation to be read by the OMR scanner on thesystem. Normally, there are several of these OMR marksprinted in a group in one area on the paper (away from anytext, pictures, or other lines) where the OMR scanner “reads”or scans them.

What is OMR?

4-2

What Do OMR Marks Look Like on Paper?The example below shows OMR marks that may be typicallyused on a document for the DI350:

Example of OMR Marks on a Document (not drawn to scale)

This is a test last page for a collation. This is a test page for acollation. This is a test page for a collation.

This is a test page for a collation. This is a test page for acollation. This is a test page for a collation.

This is a test page for a collation. This is a test page for acollation. This is a test page for a collation. This is a test pagefor a collation. This is a test page for a collation. This is a testpage for a collation.



This is a test page for a collation. This is a test page for acollation. This is a test page for a collation. This is a test pagefor a collation. This is a test page for a collation. This is a testpage for a collation.

Sincerely,

John Smith,Solicitor General

OMR Marks

OMR Marks Being Read by a DI350 Scanner

{Feed Direction(for this example)

What is OMR?

4-3

How are OMR Marks Read on the DI350?There are two OMR scanners (the devices that “read” theOMR marks) on the DI350 inserter. One is top-mounted onsheet feeder 1 and the other is bottom-mounted on the sheetfeeder 2 (see figures below).

Top-MountedOMR Scanner onSheet Feeder 1(upper)

Bottom-Mounted OMRScanner onSheet Feeder 2(lower )

What is OMR?

4-4

How are OMR Marks Generated?There are several ways to print the special OMR marks on adocument. Pitney Bowes offers a PC-based product called PBFIRST™ that enables you to add the OMR marks to yourdocuments so they can be read by the DI350 inserter (it alsoallows you to setup OMR marks for the DI400 and DI800inserters). What’s nice is that once you’ve setup PB FIRST™correctly to generate the marks, the marks are printed to theproper specifications – no “experimentation” is necessary.

If you have a computer/IT department in your organization, youmay be able to use them also as a resource to create and printthe OMR marks for you, based on the DI350 OMR specifica-tions given in this chapter (see pages 4-25 and 4-26).

Additional information on implementing OMR marks can befound in Pitney Bowes publication SV40193 and the OMRtemplate that are included with your DI350 inserter.

The top-mounted scanner reads the marks from on top of thesheet, while the bottom-mounted scanner reads the marksfrom underneath the sheet of paper. This configuration allowsyou the maximum flexibility for your document folding needswhen processed through the system. Specifically:

• the top-mounted scanner supports C-fold and double folddocuments so the address can be visible in window envelopes• that bottom-mounted scanner supports Z and half-folddocuments so the address can be visible in window envelopes

IMPORTANT: Unless you (or your organization) has hadprevious experience working with OMR marks or PB FIRST™,we recommend that you have a Pitney Bowes Consultantsetup your OMR marks for you (at a cost to be estimated).Pitney Bowes does not cover the implementation of OMRmarks on your documents under the standard supportagreements for the DI350 inserter.

What is OMR?

4-5

What OMR Marks are Used on the DI350?The DI350 has two feature levels of OMR – the feature levelyou have depends on the level installed on your machine.

Basic Level OMR– provides basic collation set integrity andthe ability to have variable-sized collation sets (a differentnumber sheets may be fed for each document based onwhat the marks on those sheets indicate to the system). Itconsists of these marks, known as Group 1:

Group 1 (“OMR”)• Benchmark• Safety• Not EOC (end-of-collation)• Not BOC (beginning-of-collation)• Parity [even]• Retime Mark

Enhanced Level OMR – allows more flexibility in variable-size collation sets as well as greater collation set integrity.The Enhanced OMR Level allows for two additional groups ofmarks, which consist of:

Group 2 (“Select Feed”)• SF1 (feed from the other sheet feeder)• SF2 (feed from the insert feeder)• Auto-Batch• Retime Mark

Group 3 (“Sequence”)• WAS3 (wrap-around sequence)• WAS2 (wrap-around sequence)• WAS1 (wrap-around sequence)• Retime Mark

NOTE: Each group of OMR marks must be treated as one unitwhen programing and printing the marks for your documents(that is, space must be allocated for every mark within eachgroup, whether the mark is used or not). Also, Basic OMR(Group 1) is always used; Group 2 and 3 marks are optional.

What is OMR?

4-6

Overview of Group 1 OMR Marks

Parity

BM

SafetyNot EOCNot BOC

Retime

OMR Group 1 Marks (Basic)

}Group 1 Marks - Mandatory

Feed Direction(for this example)

Group 1(Mandatory)

Description How it Works When You WouldUse Mark

Benchmark (BM) Identifies the start of theOMR marks on a sheet

Mark always appearsat beginning of OMRmarks

Mandatory forOMR on DI350

Safety Determines the linespacing of the OMRmarks.

The measurement ofthe space between theBM and the Safetymarks becomes thestandard of what thesystem should expectin the space betweenall the subsequentOMR marks on thatdocument. Markalways appears.


Not EOC (End-of-Collation)

Identifies the last sheet(as fed into the system)of a collated set

When mark appearson a sheet, indicates tosystem the end of acollated set


Not BOC (Beginning-of-Collation)

Identifies the first sheet(as fed into the system)of a collated set

When mark appearson a sheet, indicates tosystem the start of anew collated set


Parity Helps in the detection ofmisread OMR marks ona sheet

Verifies that thenumber of OMR marksis even.


Retime Indicates the end ofOMR marks for Group 1

Mark always appears.Helps the systemsavoid “losing its place” when tracking themarks


What is OMR?

4-7

Parity

BM

SafetyNot EOC

Retime

Auto-Batch

SF1SF2

Retime

Not BOC }Group 1 Marks - Mandatory

} Group 2 Marks (“Select Feed” ) - Optional

OMR Group 1 and 2 Marks (Enhanced Level)


Overview of Group 2 OMR Marks

Group 2(Optional)


Select Feed 1(SF1)

Dynamically turns onand off the other sheetfeeder as necessary foreach collated set.

Presence of a markindicates that the othersheet feeder feeds onesheet. The absence ofthe mark indicates thatother feeder willoperate in pass-through mode for theindicated collated set.

For feedingadditional full-page sheets fromthe other sheetfeeder asnecessary to addto collated sets

Select Feed 2(SF2)

Dynamically turns onand off the insert feederas necessary for eachcollated set.

Presence of a markindicates that the insertfeeder feeds onesheet. The absence ofthe mark indicates thatthe insert feeder willoperate in pass-through mode for theindicated collated set.

For feedinginserts from theinsert feeder asnecessary to addto collated sets

Auto-Batch Instructs the system tostop (but not end) thejob when it encountersa collated set whichcontains this mark

Presence of a markindicates that systemshould stop after thiscollated set. This markmust be on all pageswithin the collated set.

For separatingcollated sets thatmay need specialhandling (like amail tray) withinthe same job run


Mark always appears.Helps the systemsavoid “losing its place” when tracking themarks

Mandatory whenusing this OMRGroup on DI350

What is OMR?

4-8

OMR Group 1, 2, and 3 Marks (Enhanced Level)

Parity

BM


Retime

Auto-Batch

SF1SF2

Retime

WAS1

WAS3WAS2

Retime


}}

Group 2 Marks (“Select Feed” ) - Optional

Group 3 Marks (“Sequence”) - Optional


Overview of Group 3 OMR MarksGroup 3(Optional)


Wrap-AroundSequence (WAS3)

Allows the system totrack each sheet fromthe feeder by a numbersequence. Thenumbers repeat, or"wrap-around", whenthey come to the end ofthe sequence, with thesequence repeating asmore sheets are fed.The system reads themarks in ascendingorder (as in 0, 1, 2, 3, 4,5, 6, 7, 0, 1, 2, 3, 4...).

The sequence ofnumbers (from 0-7) isbased on thecombinations that canbe created in binaryformat from three OMRmarks (see chart).Withthe proper sequenceprinted on allmailpieces, the systemeasily detects when asheet is not fed in theproper order. Markappears as necessaryto create binarynumber sequence.

For greatercollated setintegrity, such as in high-sensitivityjobs.


Part of above Mark appears asnecessary to createbinary numbersequence

Part of above


Part of above Mark appears asnecessary to createbinary numbersequence

Part of above


Mark always appears.Helps the systemsavoid “losing its place” when tracking themarks.

Mandatory whenusing this OMRGroup on DI350

What is OMR?

4-9

OMR Group 1 and 3 Marks (Enhanced Level)


}Parity

BM


Retime

WAS1

WAS3WAS2

Retime

OMR Group CombinationsUnder Enhanced Level OMR, you have the option of addingGroup 2 marks, Group 3 marks, both groups, or no groups toBasic OMR (Group 1). Groups must be contiguous, that is, ifyou are not using Group 2, Group 3 marks must immediatelyfollow Group 1 (see figure below). In every case, you mustalways select Basic Level OMR before choosing the optionalGroup 2 and/or Group 3 marks.

Basic OMR Enhanced OMR

Group 1Marks

Group 2Marks

Group 3Marks

✔

✔ ✔

✔ ✔ ✔

✔ ✔

OMR Group Combinations Table


The table below lists the combination of OMR groups thatmay be used together.


What is OMR?

4-10

Details of Basic Level OMRBasic Level OMR consists of six OMR marks, which make upGroup 1. Space must be allocated for every mark in the group,whether the mark is used or not. In the OMR job setup on thesystem control panel, Group 1 is referred as simply “OMR”.

Group 1 Marks - Mandatory} Group 1 Marks (“OMR”) • Benchmark (BM)

The Benchmark (BM) is the first OMR mark scanned andmust be on every page in a collated set. This mark indicatesto the system the start of the OMR marks on a page.

• SafetyThe Safety mark is the second OMR mark scanned and mustbe on every page in a collated set. It used to determine theline spacing of the OMR marks. Specifically, the measure-ment of the space between the BM and the Safety marksbecomes the standard of what the system should expect inthe space between all the subsequent OMR marks on thatdocument.

• Not End-Of-Collation (EOC)The Not End-Of-Collation (EOC) mark is the third OMR markscanned and must be on every page in a collated set, exceptthe last page fed into the system (which is the first printedpage of a document). When the system reads a Not EOCmark on a sheet, it knows that this is the not the last page ofa collated set. However, when it doesn’t see a Not EOCmark, it knows this is the last page of a collated set. Thisfeature allows different size collated sets to be processed onthe DI350 inserter.

Parity

BM


Retime

OMR Group 1 Marks (Basic)Feed Direction(for this example)

What is OMR?

4-11

While the feeders within the system have double detectionsensors, a combination of paper slippage and other variablescould result in two full collated sets being mailed as one. TheNot EOC configuration adds the benefit in that it avoidsputting two documents into a single envelope if the Not EOCmark is ever missed by the scanner.

• Not Beginning-Of-Collation (BOC)The Not Beginning-Of-Collation (BOC) mark is the fourthOMR mark scanned and must be on every page in a collatedset, except the first page fed into the system (which is thelast printed page of a document). When the system reads aNot BOC mark on a sheet, it knows that this is the not thefirst page of a collated set. However, when it doesn’t see aNot BOC mark, it knows this is the first page of a collated set.This provides additional verification that a collated set is notbeing split or combined with another collated set into onepackage.

• Parity (even)The Parity mark is the fifth OMR mark scanned, but becauseof how it is used, it may or may not be printed on every pagein a collated set. The Parity mark is used to ensure that thetotal number of OMR marks read by the scanner on onepiece of paper is always an even number. This provides aninternal check on the scan set of marks on a single sheet andhelps detect sensitivity problems associated with the scanneror excessive paper skew. Because the system checks for aneven number of marks, it is known as “even” parity (if thesystem checked for an odd number, it would be called “odd”parity).

What is OMR?

4-12

For example, for a one-page document, the marks printed onthe page are:

BM 1 markSafety 1 markNot EOC 0 mark (not printed, as it is the end of document)Not BOC 0 mark (not printed, as it is the start of document)Retime 1 mark (see description below)------------------------Total = 3 marks (odd number; needs Parity mark)

Parity + 1 mark--------------------------New total= 4 marks (even number; all OK)

In this example, the Parity mark is printed on this page tomake the number of marks go from odd (3) to even (4).

As another example, for the last page fed of a two-pagecollated set, the marks printed on the page are:

BM 1 markSafety 1 markNot EOC 0 mark (not printed, as it is the end of collated set)Not BOC 1 markRetime 1 mark------------------------Total = 4 marks (even number; all OK, no Parity mark)

Parity + 0 mark (not printed, as it is not needed)--------------------------New total= 4 marks (even number; all OK)

In this example, the Parity mark is not printed on this pagebecause the total number of marks is even (4) to begin with.

• RetimeThe Retime mark is the last OMR mark scanned and must beon every page in a collated set. This mark indicates to thesystem the end of OMR marks for Group 1 and helps thesystems avoid “losing its place” when tracking the marks.

What is OMR?

4-13

Example of Group 1 Marks Printed on SeveralDocuments for Feeding from Sheet Feeder 1

Safety

Retime

ParityNot BOCNot EOC

BM

Mr. John Doe333 Marble Dr.Anytown, USA 33333

Dear Mr. Customer:

This is a test last page for a collation. This is atest last page for a collation. This is a test lastpage for a collation.




Page 1 of Document 3(fed last from feeder)

Retime

Not EOCNot BOCSafetyBM

Parity

Page 2 of Document 3

Retime


Parity

This is a test second page for a collation. This isa test last page for a collation. This is a test lastpage for a collation.










Respectfully Yours,

ABC Company

Retime


Parity

Document 2 (one page)

Retime


Parity

Mrs. Jane Hancock111 Maple St.Anytown, USA 11111

Dear Mr. Customer:


This is a test last page for a collation. This is atest last page for a collation. This is a test lastpage for a collation.llation. This is a test last page for a collation.

Respectfully Yours,

ABC Company


Dear Mr. Customer:





Retime


Parity




Respectfully Yours,

ABC Company

Page 2 of Document 1(fed first from feeder)

Feed Direction

Retime


Parity


What is OMR?

4-14

Details of Enhanced Level OMREnhanced Level OMR adds the availability of two additionalgroups of marks, Groups 2 and 3. Like Group 1 marks, spacemust be allocated for every mark within each group, whetherthe mark is used or not.

Under Enhanced Level OMR, you have the option of addingGroup 2 marks, Group 3 marks, both groups, or no groups toBasic OMR (Group 1). Groups must be contiguous, that is, ifyou are not using Group 2, Group 3 marks must immediatelyfollow Group 1. In every case, you must always select BasicLevel OMR before choosing the optional Group 2 and/orGroup 3 marks. The table below lists the combination of OMRgroups that may be used together.

Basic OMR Enhanced OMR

Group 1Marks

Group 2Marks

Group 3Marks

✔

✔ ✔

✔ ✔ ✔

✔ ✔

OMR Group Combinations

Group 2 Marks (“Select Feed”)In the OMR job setup on the system control panel, Group 2marks are referred to as “Select Feed”.

OMR Group 2 Marks (“Select Feed” ) - OptionalFeed Direction(for this example)

Auto-Batch

SF1SF2

Retime

What is OMR?

4-15

• Selective Feed 1 (SF1)Selective Feed marks in general are used in applicationswhere some pages are not fed as part of the initial collatedset for certain mailpieces (e.g., perhaps confidential orrestricted information should not be sent to each individual ina mailing). The Select Feed 1 mark specifically allows you todynamically turn on and off the other sheet feeder for eachcollated set. For example, if you are feeding your control(also known as the main or prime) document from the uppersheet feeder, SF1 would allow you to feed from the lowersheet feeder as necessary.

Presence of a mark indicates that the other sheet feederfeeds one sheet. The absence of the mark indicates thatother feeder will operate in pass-through mode for the indi-cated collated set. NOTE: The same selective feed markpattern must be on all sheets within a collated set.

• Selective Feed 2 (SF2)You can use also dynamically turn on and off the insertfeeder as necessary for each collated set using the SelectiveFeed 2 mark on the control document. Presence of a markindicates that the insert feeder feeds one sheet. The absenceof the mark indicates that the insert feeder will operate inpass-through mode for the indicated collated set. NOTE: Thesame selective feed mark pattern must be on all sheetswithin a collated set.

• Auto-BatchAn Auto-batch mark instructs the system to stop (but notend) the job after it processes a collated set which contains theAuto-batch mark. This allows you to separate collated setsthat may need special handling (like a mail tray) within thesame job run. NOTE: The same Auto-batch marks must beon all sheets within a collated set.

• RetimeThis Retime mark must be on every page within a collated set.It indicates to the system the end of this group of OMR markson a page and helps the systems avoid “losing its place”when tracking the marks.

What is OMR?

4-16


Dear Mr. Customer:






Retime


Parity

Auto-BatchSF2SF1

Retime

Example of Group 1 and 2 Marks Printed on SeveralDocuments for Feeding from Sheet Feeder 1

Retime

RetimeAuto-batchSF2

Parity

Safety

Not BOC

Not EOC

BM

SF1

Legend of OMR Features on Documents








Retime


Parity

RetimeAuto-BatchSF2SF1





Respectfully Yours,

ABC Company

Retime


Parity




Dear Mr. Customer:



Respectfully Yours,

ABC Company

Retime


Parity


BM


Dear Mr. Customer:





Retime

Not EOCNot BOCSafety

Parity

SF2SF1

RetimeAuto-Batch

Feed Direction




Respectfully Yours,

ABC Company


Retime


Parity


Feature Document 1 Document 2 Document 3

Select Feed 1-SF1(feed page fromsupplementaryfeeder)

✔ ✔

Select Feed 2-SF2(feed page from insertfeeder)

✔

Auto-Batch (stop jobafter processing thisdocument)

✔


What is OMR?

4-17

OMR Group 3 Marks (“Sequence”) - Optional

• Wrap-Around Sequence (WAS) - 3 mark positionsWrap-Around Sequence (WAS) marks add to mailpieceintegrity by allowing the system to track each sheet from thefeeder by a number sequence. The numbers repeat, or"wrap-around", when they come to the end of the sequence,with the sequence repeating as more sheets are fed. Thesystem reads the marks in ascending order (as in 0, 1, 2, 3,4, 5, 6, 7, 0, 1, 2, 3, 4...).

With the proper sequence printed on all mailpieces, thesystem easily detects when a sheet is not fed in the properorder. After an out-of-sequence feeding or an OMR scanerror is detected and cleared, the system will begin fresh withthe sequence number of the next document that is fed.

This sequence of numbers (from 0-7) is based on the combi-nations that can be created in binary format from three OMRmarks. The figure on the next page shows how the numbercombinations are created by the three marks within thespace allocated to WAS.

• RetimeThis Retime mark must be on every page within a collatedset. It indicates to the system the end of this group of OMRmarks on a page and helps the systems avoid “losing itsplace” when tracking the marks.


Group 3 Marks (“Sequence”)In the OMR job setup on the system control panel, Group 3marks are referred to as “Sequence”.

WAS1

WAS3WAS2

Retime

What is OMR?

4-18

mark not printed(position left blank)

Sequence Creation Using Wrap-Around Sequence (WAS) Marks

WAS1

WAS3WAS2 } Sequence #6

WAS1


WAS1


}WAS1

WAS3WAS2 Sequence #4

WAS1


WAS1


WAS1


WAS1



What is OMR?

4-19

Example of Group 1, 2, and 3 Marks Printed onDocuments for Feeding from Sheet Feeder 1

Retime

Retime

WAS1WAS2WAS3

Auto-Batch

Retime

SF2SF1

Parity

Safety

Not BOC

Not EOC

BM


Dear Mr. Customer:






Retime


Parity

Auto-BatchSF2SF1

Retime

WAS2WAS3

WAS1Retime








Retime


Parity


WAS1WAS2WAS3

Retime





Respectfully Yours,

ABC Company

Retime


Parity


RetimeWAS1WAS2WAS3



Dear Mr. Customer:



Respectfully Yours,

ABC Company

Retime


Parity


RetimeWAS1WAS2WAS3

Legend of OMRFeatures on Documents

Feature Document 1 Document 2 Document 3

Select Feed 1-SF1(feed page fromsupplementaryfeeder)

✔ ✔

Select Feed 2-SF2(feed page from insertfeeder)

✔

Auto-Batch (stop jobafter processing thisdocument)

✔

Wrap-AroundSequence - WAS1,WAS2, WAS3(sequentialnumbering of pagesfrom 0 to 7)

✔

Page 2 = "0"Page 1 = "1"

✔

Page 1 = "3"

✔

Page 3 = "4"Page 2 = "5"Page 1 = "6"



Dear Mr. Customer:





Retime


Parity

SF2SF1

RetimeAuto-Batch

WAS3WAS2

RetimeWAS1

Feed Direction


Retime


Parity


RetimeWAS1WAS2WAS3




Respectfully Yours,

ABC Company

What is OMR?

4-20

Considerations When Implementing OMRBefore implementing any of the DI350 OMR marks, you mustconsider various aspects of document preparation, OMR markcombinations, and system feeding. By being aware of themechanical and electronic interaction of the system with OMRscanning, you can select the OMR features that work best withyour applications.

Document Loaded onto Feederas Printed (in reverse order)

12

3

32

Machine Feeds Pages from Topand Reverses Order When Collating(figure doesn't show folding)

Document Page Order from Creation to Final Output from DI350

32

1

Completed Document in Envelope inNormal Order, Address Page on Top orin Window (figure doesn't show folding)

32

1

Multi-Page Document Created inApplication (pages in normal

order, address page first)

Document Printed(pages in reverse order,address page on bottom)

12

3

1 2

3 4

5

What is OMR?

4-21

Head of Page

View of Mark Order and Position onPage as Printed for Sheet Feeder 1

Parity

BM


Retime

Auto-Batch

SF1SF2

Retime

WAS1

WAS3WAS2

Retime


}}



Foot of Page

What is OMR?

4-22

{Group 1 Marks - Mandatory

{{

Parity

BM

Safety

Not BOC

Retime

Auto-Batch

SF1

SF2

Retime

WAS3

WAS1WAS2

Retime

Not EOC

Feed Direction

Head of Page, Face-Up



View of Mark Order and Position on Page as Loadedfor Sheet Feeder 1 (Face-Up, Head-First)

Scanner

Foot of Page

What is OMR?

4-23

View of OMR Mark Order and Position onPage as Printed for Sheet Feeder 2

Head of Page

{

Group 1 Marks - Mandatory

{{



Parity

BM

Safety

Not BOC

Retime

Auto-Batch

SF1

SF2

Retime

WAS3

WAS2

Retime

Not EOC

WAS1

Foot of Page

What is OMR?

4-24

denotes mark is onother side of paper


}}



View of Mark Order and Position on Page as Loadedfor Sheet Feeder 2 (Face-Down, Feet-First)

Foot of Page, Face-Down

Feed Direction

Parity

BM

Safety

Not BOC

Retime

Auto-Batch

SF1

SF2

Retime

WAS3

WAS2

Retime

Not EOC

WAS1

Scanner

Head of Page

What is OMR?

4-25

OMR Printing/Feeding Considerations Based on Fold Type

Maximum Sheets Per Collation Set

Sheets Fed fromControl DocumentFeeder

Sheets Fed fromSupplementaryFeeder

Sheets Fed fromInsert Feeder

Total SheetsPermissible in Collation Set(Envelope)

1 to 5 1 1 up to 7

Fold Type Area Requiredon Paper forPrinting OMRMarks andLeaving SpaceAround Them

Where OMR Marks arePrinted onPaper

Order of Pages WhenPrInting andPresenting toFeeder

Loading ofDocuments onto System

C-Fold 4.5 inches(115mm) longand 3/4” (14 mm)wide column

Upper leftside of thepaper

Reverse(addresspage is last page printedand last pagefed for eachdocument set)

Sheet Feeder 1 (face up, head first )

Double Fold 4.5 inches(115mm) longand 3/4” (14 mm)wide column

Upper leftside of thepaper

Reverse Sheet Feeder 1 (face up, head first )

Z-Fold 4 inches(100mm) longand 3/4” (14 mm)wide column

Lower rightside of thepaper

Reverse Sheet Feeder 2 (face down, feet first )

Single Fold(Half Fold)

4 inches(100mm) longand 3/4” (14 mm)wide column

Lower rightside of thepaper

Reverse Sheet Feeder 2 (face down, feet first )

What is OMR?

4-26

OMR Printing Specifications Template(see SV40193-TM for full-size version of this template)

SV40193-TM Rev. A 9/02

MARK SPECIFICATIONS

• A clear area of 115mm is required from the top left corner of the form (top scan) and 100mm from the bottom right corner of the form (bottom scan).• - black ink on a white background• - 10mm min• - 1 pt min / 2 pt max• Spacing - 3mm min between marks• Clearance - 2mm min on either side

DI350/DI400 Inserting Systems Scanning Template

_____ Benchmark_____ Safety_____ NOT-End of Collation (NOT-EOC)_____ NOT-Beginning of Collation (NOT-BOC)_____ Parity (even)_____ Re-time mark _____ Select Feed 1 (SF1)_____ Select Feed 2 (SF2)_____ Auto-batch_____ Re-time mark (Fixed if this group is in use)_____ Wrap Around Sequence 3 (WAS3)_____ Wrap Around Sequence 2 (WAS2)_____ Wrap Around Sequence 1 (WAS1)_____ Re-time mark (Fixed if this group is in use)

Group 1

Group 2

Group 3

Vertically CenterGroup withinBracket

2mm White Space(on both sides of mark)

ace2mm White Spaark)(on both sides of ma

96mm max

54mm min

115mm min

Vertically CenterGroup within

Bracket

69mm max

27mm min

100mm min

DI350/DI400 OMR INFORMATION

• IMPORTANT: Unless you (or your organization) has had previous experience working with OMR marks or PB FIRST software, we recommend that you have a Pitney Bowes consultant set up your OMR marks for you (at a cost to be estimated). Pitney Bowes does not cover the implementation of OMR marks on your documents under the standard support agreements for the DI350/DI400 systems.• Before using template, read the accompanying guidelines.• OMR is available on the three station machines ONLY.• The minimum scan line requirement is all of Group 1.

DI350/DI400 SCAN MARK POSITIONINGCANNOT DO PART OF A GROUP - ALL OR NOTHING

Create OMR Job

5-1

5. CREATE OMR JOB

This section takes you step-by-step through the process ofsetting up a new OMR job and saving it in the memory. TheOMR function is available only on the three-station model. Thismodel can be programmed with up to 20 jobs.

What is OMR (Optical Mark Recognition)?An OMR mark is normally a dark solid line on a sheet of lightcolored paper that is horizontally printed so it matches thedirection of travel of the paper. This line must be sufficientlythick and dense to trigger the OMR scanner on the system.

The OMR scanner, working with the OMR system software,checks for one or more different OMR marks on a documentwhile it is fed through the system. The tracking of these OMRmarks by the system increases the chance that a set ofsheets which belong together (a collation set) actually staystogether throughout the inserting process. See Chapter 3,“What is OMR?” for more information.

Programming is carried out in the ‘Setup Mode’…

Entering the Setup ModeOpen the hinged cover to theright of the display. This willexpose the setup buttons.Press Setup. The indicatorwill light and the machine willask for an access code. Thiscode prevents the machine’ssettings being changed byunauthorized personnel.

The Prev ( ) and Next ( ) buttons are used to stepforward or backwards through the settings available. Oncethe item is displayed, the Change (+/-) buttons are used toselect the option you want.

Create OMR Job

5-2

Use the Change (+/-) buttonsto select the access code 71.

Press Next ( ) to advanceto the next setting…

Choosing the New Job NumberThe machine will ask for thejob number you wish the newsettings to be stored under(the default job number is 1).Use the Change (+/-) buttonsto display the job number youwant.

Notes:• If you use an existing job number, the old settings will be

overwritten by the new settings you are about to make.• If you want to find a

currently unused jobnumber, press Change(+/-) until you see a jobwhere the display showsno symbols alongside thefeeders or in the foldsetup area. This means the job is currently empty.


Create OMR Job

5-3

Selecting the OMR FunctionsPress Change (+/-) until you see the option you want:

OMR off – OMR is turned off for this job.

OMR on – OMR (OMR Group 1 marks) is turned on forthis job.

If your machine has the Enhanced level of OMR, theseoptions will also display:

OMR + Sequence – Basic scanning + page sequencescanning for this job (OMR Groups 1 and 3).

OMR + Select feed + Sequence – Basic scanning +Select Feed/Auto-Batch + Page sequence scanning forthis job (OMR Groups 1, 2, and 3).

OMR + Select feed – Basic scanning + Select Feed/Auto-Batch scanning for this job (OMR Groups 1 and 2).

See Chapter 3, “What is OMR?” for more information on theOMR marks and groups and what they mean.

NOTE: A maximum of FIVE pages per set can be fed fromeither sheet feeder 1 or 2 when using the OMR function.

Press Next ( ) to advance to the next setting...(see page 5-6)

The flowchart on the following pages describe the setup forthe various OMR functions.

Create OMR Job

5-4

Open hinged cover on right side of control panel and press Setup key

Use +/ - keys to enter 71 for access code, then press > key

Use +/ - keys to enter job number, then press > key

Use + /- keys to select OMR function, then press > key

Use + / - keys to select whether the main (scanning) sheet feeder is On with


OMR off OMR onOMR +

SequenceOMR + Select

Feed + SequenceOMR + Select

Feed

Use + / - keys to select whether other sheet feeder is Off, On with


Base Level Enhanced

Use +/ - keys to select fold type (c-letter, z-accordion, double, single),

then press > key

Level Only

Use +/ - keys to select whether other sheet feeder is:O f fOn with double detectOn with no double detectOn with select feedOn with select feed and double detect,then press > key

Non-Select Feed Options Select Feed Options

See Separate Flowchart for Non-OMR Job

Flowchart for OMR Job Setup (Both Levels)


Create OMR Job

5-5

Flowchart for OMR Job Setup (Both Levels)

continued from previous page

Use + /- keys to select whether insert feeder is Off, On with


Use + /- keys to select whether sealer is Off or On, then press > key

Use + /- keys to change paper length of your sheets, then press > key

Use + /- keys to change Fold A setting (if neccesary), then press > key to

continue

Use + / - keys to change Fold B setting (if neccesary), then

press > key to continue

Use + / - keys to change envelope depth, then press > key

Use +/ - keys to change envelope stop setting, then press > key

Use +/ - keys to select whether batch mode is Off or On, then press > key

Use + / - keys to enter batch counter (from 50 to 999),

then press > key

Job number displays (back at beginining)

Use + /- keys to select whether insert feeder is:O f fOn with double detectOn with no double detectOn with select feedOn with select feed and double detect,then press > key

Sequence Options

Single Fold C, Z, Double Folds

Batch OnBatch Off

Non-Sequence Options

Create OMR Job

5-6

When the fold type is set as required, press Next ( ) toadvance to the next setting…

Fold TypeSelect the type of fold.

Press Change (+/-) until yousee the option you want:

C - Letter Folds your sheet into astandard ‘C’ or letter fold.

Z - Accordion Folds your sheet into a ‘Z’or accordion fold.

Double Folds your sheet inhalf and then in half again.

Single Folds your sheet once.

When you select either C-Letter fold or a double fold, themachine will automatically select the TOP Sheet Feeder 1as the scanning feeder. If you select either a Z-AccordionFold or a single fold, the machine will automatically select theBOTTOM Sheet Feeder 2 as the scanning feeder.

Create OMR Job

5-7

Setting the Main (Scanning) Sheet FeederPress Change (+/-) until you see the option you want:

On Double Detect Feeder onwith the double detectoroperating. (The doubledetector stops the machine ifmore than one sheet simultan-eously feeds from the feeder).

On Feeder on without the double detector.

When the Sheet Feeder is set as required, press Next ( )to advance to the next setting…

Setting Other Sheet FeederSelect whether you want to use the other sheet feeder (it maybe feeder 1 or 2, dependingon what feeder was chosenas the main sheet feederbased on fold type in theprevious step). This function isavailable only on the three-station model.

Press Change (+/-) until you see the option you want.

If you had chosen OMR or OMR + Sequence as your OMRoption earlier, the following choices are available:

On Double Detect Feeder on with the double detectoroperating. (The double detector stops the machine if morethan one sheet simultaneously feeds from the feeder).

On Feeder on without the double detector

Off select feeder turned off for this job.

Create OMR Job

5-8

On Double Detect Feeder on with the double detectoroperating. (The double detector stops the machine if morethan one sheet simultan-eously feeds from the feeder).



On SF Double Detect Select feeder is on with the doubledetector operating. (The double detector stops the machine ifmore than one insert simultaneously feeds from the feeder).

On SF Select feeder on without the double detector.

When the feeder is set as required, press Next ( ) toadvance to the next setting…

If you had chosen OMR + Select Feed or OMR + SelectFeed + Sequence as your OMR option earlier, the followingchoices are available:

Create OMR Job

5-9

Setting Insert FeederSelect whether you want touse the insert feeder. Thisfunction is available only onthe two and three-stationmodels.

Press Change (+/-) until you see the option you want.

If you had chosen OMR or OMR + Select Feed as your OMRoption earlier, the following choices are available:




If you had chosen OMR + Sequence or OMR + Select Feed+ Sequence as your OMR option earlier, the followingchoices are available:



Off select feeder turned off for this job

On SF Double Detect Select feeder is on with the doubledetector operating. (The double detector stops the machine ifmore than one insert simultaneously feeds from the feeder).

On SF Select feeder on without the double detector.

When the other feeder is set as required, press Next ( ) toadvance to the next setting…

Create OMR Job

5-10

Paper LengthSelect the paper length.

Use the scale on the edge ofthe stacker.

Quick reference: US Letter length 11" (279mm) A4 paper length 297mm

Press Change (+/-) until the length of your paper (inmillimeters) is displayed.

When the paper length is correct, press Next ( ) to advanceto the next setting…

SealerSelect whether you want to sealenvelopes or not.

Press Change (+/-) to switchthe option on or off:

On Turns the sealer unit on for automatic sealing ofenvelopes. Make sure the sealer water bottle is fullof EZ Seal® or water (see page 2-8).

Off Turns the sealer unit off. Envelopes will be ejectedunsealed.

When the sealer is set as required, press Next ( ) to advanceto the next setting…

If you have selected either of the Sheet Feeders, the nextsetting offered will be Fold Type. However, if you are usingthe Insert Feeder only, folding is not possible and themachine will advance directly to the Envelope Depth setting(page 5-12).

Create OMR Job

5-11

Fold ASelect the size of the firstfold required.

Depending on the settingspreviously made for fold typeand paper length, the machine will be suggesting the correctdimension for the first fold. Most times, therefore, this settingwill not require alteration.

If you want to change the ‘standard’ setting, press Change(+/-) until the length of fold required is displayed. The symbol| –––– | shows the fold panelyou are adjusting.

The machine willautomatically limit yourchoices to what is physicallypossible within the machinespecifications. (As you change the length of Fold A, you willsee the dimension of Fold B automatically changing to keepwithin paper length and machine specifications.)

When the setting is correct, press Next ( ) to advance tothe next setting…

Fold BNOTE: This setting does notdisplay when Single fold hasbeen chosen. Select the sizeof the second fold required.

In a similar way to fold A, themachine will be suggesting the correct dimension for the fold.

If you want to change the ‘standard’ setting, press Change(+/-) until the length of fold required is displayed. The symbol| –––– | shows the fold panel you are adjusting.

When the setting is correct, press Next ( ) to advance to thenext setting…

Create OMR Job

5-12

Envelope DepthSelect the depth of your envelopes (in millimeters).

Again, you can use the scale on the stacker to measure thedepth of your envelopes.Press Change (+/-) until thecorrect dimension isdisplayed. When theenvelope depth is set asrequired, press Next ( ) toadvance to the next setting…

Envelope StopSelect the position of the machine’s envelope stop.

The stop has five positionsnumbered 1 to 5. Setting 3 isthe ‘standard’ setting fornormal weight paper withstandard folds. A thinner/lighter envelope will require alower setting and thicker/heavier envelope a higher setting.

Press Change (+/-) until the setting you want is displayed.

When the envelope stop is set as required, press Next ( ) toadvance to the next setting…

Create OMR Job

5-13

Batch ModeThe Batch Mode allows you to automatically process pre-defined batches of finished mailpieces. The system “countsdown” from the number programmed for that job. When thebatch is complete (has reached “0”), the machine will stop,allowing you to empty the stacker. Pressing Start willcommence processing of the next batch.

If Batch Mode is not selected, the display counter will simplycount the number of items processed until reset by pressingReset Counter.

Press Change (+/-) to switchBatch Mode On or Off.

When the setting is correct,press Next ( ).

If Batch Mode is turned On,the machine will now requestthe batch quantity. Thedefault quantity is 50, but youmay select any value up to999 using the Change (+/-)buttons.

When the setting is correct, press Next ( ).

Confirming the Job SetupJob setup is now complete.The display will show thecomplete job setup for you toconfirm. If you see a settingthat is incorrect, use the Prev( ) button to backtrack to the setting and correct it.

When you are satisfied with the program, press the Setupbutton. The machine will save the job into its memory andreset to the new job.

Create OMR Job

5-14

Adjustment of OMR Scanner(for first-time use or if a change in OMR has been made)

In order for the OMR scanning to function correctly, it isimportant to ensure that the scanning heads are positioned inline with the scan dash marks printed on the material.

In order to locate the scanning head for the top sheet feeder1, open the top cover. The scanning head can be found atthe rear of the machine.

In order to locate the scanning head for the bottom sheetfeeder 2, remove both sheet feeder 2 and the fold platesituated below sheet feeder 2. The scanning head can befound mounted to the front of the machine.

Bottom SheetFeeder Scanner

Top Sheet FeederScanner

When this is complete, thedisplay will show the new jobwith the message ‘Trial PieceRequired’.

Job settings will be retained by the system even with powerdisconnected until they are changed or deleted as describedon page 5-18.

Create OMR Job

5-15

Fold a sheet of material in half and measure the distancefrom the side of the form to the middle (for an 8-1/2” x 11”form, this measurement is 4-1/4”).

Now measure the distance from the edge of the form to themiddle of the scan dash marks (see figure on next page), andsubtract this measurement from the half fold measurement.Use the table (also on the next page) to convert thismeasurement into the setting for the scanning head.

For example, on an 8-1/2” x 11” form, the half foldmeasurement is 4-1/4”. If the distance from the edge of theform to the middle of the scan dash marks is 3/8”, thescanning head distance is 3-7/8” (4-1/4 – 3/8). For 3-7/8”, thistranslates to a setting of 98 on the scan head.

Loosen the knurled locking knob and set the appropriatescanning head to the correct setting. If the machine is turnedon, you will notice a blue color emanating from the scanner.For the top scanner, the blue light shines on top of the paper;while on the bottom scanner, the light shines from beneaththe paper. This is normal and will help you determine thecorrect position of the scanner.

Scanner Head Locking Knob

Ruler for Setting Scanner Position

When finished, retighten the locking knob.

If you have adjusted the bottom sheet feeder scanner, refitboth sheet feeder 2 and the fold plate situated below sheetfeeder 2.

Create OMR Job

5-16

105mm

10mm

TopScanning

10mm

BottomScanning

4-1/4”

3/8”

3/8”

Example of Measuring Distance of OMR Marks on8-1/2” x 11” Paper for Proper Setting of Scan Head

Distance between center ofOMR marks and center of page(in inches)

Scanner HeadSetting

3-1/2" 89

3-5/8" 92

3-3/4" 95

3-7/8" 98

4" 102

3-7/8”

3-7/8”

Create OMR Job

5-17

Loading the MaterialMaterial for all OMR jobs are loaded in reverse order towhich they are printed. This allows the address page for thedocument set to be the last page fed but the first pageshowing on top of the set after it has been collated andfolded. See the table below.

Fold Type Order of Pages WhenPresented to Feeder

Loading of Documentson to System

C-Fold Reverse(address page is last pageprinted and last page fedfor each document set)

Sheet Feeder 1 - upper(face up, head first )

Double Fold Reverse Sheet Feeder 1- upper(face up, head first )

Z-Fold Reverse Sheet Feeder 2 - lower(face down, feet first )

Single Fold(Half Fold)

Reverse Sheet Feeder 2 - lower(face down, feet first )

When preparing material for use in the lower feeder (forOMR jobs using a single fold or Z-fold), it is suggested thatyou place the sheets from the printer face down on a tableand then take from the top of this inverted stack to load themachine. When the OMR feeder becomes empty in mid-job,you can just take another batch from the top of the stack, putit into the feeder and press Start, even if the last set isincomplete because part of it is in the stack rather than in themachine.

If you load from a face-up stack, the machine will not rununless the stack is split at exactly a set boundary. Also ifsequence checking is active and the feeder becomes empty,you cannot just re-load and press Start because the machinewill likely fail due to sequence error. Neither of theseproblems occurs if you load the machine from a face-downstack.

Create OMR Job

5-18

Testing the JobLoad material and press Trial Piece so that you can checkthat the setup is correct.

Minor changes to the job settings can be made at this stageif the trial piece needs ‘fine tuning’. Press Setup, then usethe Prev ( ), Next ( ) and Change (+/-) buttons asrequired to modify job settings. A chart is provided below tohelp ‘fine tune’ your fold settings.

FOLD TYPE ADDRESS TOO LOW ADDRESS TOO HIGH

“C” - Letter Fold Decrease Fold A Increase Fold A andincrease Fold B by thesame amount

“Z” - Accordion Increase Fold A Decrease Fold A and Fold increase Fold B

by the same amount

Single Fold Increase Fold A Decrease Fold A

Double Fold Decrease Fold A Increase Fold A

It is recommended that the folds are changed by 5mm eachtime and a new trial piece run to test the settings. When youhave made the necessary changes, press Setup again toreturn to run mode. The job will be saved with the new settings.

Create OMR Job

5-19

Changing an existing job

To change an existing job, follow the steps below:1. Enter the setup mode as described on page 5-1.

2. Use the Change (+/-) buttons to display the job you wishto edit.

3. Use the Prev ( ) and Next ( ) buttons to display thesetting(s) you wish to change.

4. Use the Change (+/-) buttons to change the options/dimensions you wish to amend.

5. Press the Setup button to leave setup mode and savethe changes.

Deleting a job

To erase an existing job from memory, follow the stepsbelow:1. Enter the setup mode as described on page 5-1.

2. Use the Change (+/-) buttons to display the job you wishto delete.

3. Press the Delete button. The display reads “Press againto confirm”. Press Delete again. The display will brieflyread ‘Deleting Job’ as the job is erased.

4. Press the Setup button to leave setup mode.

Create OMR Job

5-20

Reference

6-1

6. REFERENCE

Changing the Display Language

To change the language of the display…

1. Enter the setup mode as described on page 3-1 or 5-1.

2. Use the Change (+/-) buttons to select the access code99.

3. Press Next ( ) to select the languages option.

4. Use the Change (+/-) buttons to scroll through thelanguages. When your required language is displayed,press the Setup button to select the language and leavesetup mode

Clearing Material

Note: All the following illustrations show the three-stationmachine, although all models are similar.

The inserter has been designed to assure maximumperformance. In the event of a material stoppage, the displaywill flash the symbol indicating where the stoppage hasoccurred. First press Clear Deck to attempt to feed thematerial through the machine. If not successful, the sectionsbelow tell you how to removethe trays and plates to gainaccess to the material.

The Hand CrankHaving located the material,you may need to use thehand crank to manually feedpaper out of the grip ofrollers etc.

Reference

6-2

Reference

The hand crank is located behind the drop down cover at theleft front of the machine.

Removal & Replacement of the Sheet Feeder and EnvelopeTrays

To remove…Lift the rear of the trayslightly and pull it straightoutwards from the machine.

Note: If the tray is loaded,gently hold the material inplace to prevent it slidingforward as the tray isremoved.

To replace…Place the tray into its location guides in the side frames. Liftthe rear of the tray slightly and push it into the machine. Thetray will automatically drop into its correct location.

Removal & Replacement of the Fold Plates

To remove…Pull the two catches on theunderside of the plateoutwards to release them.Pull the plate straight outfrom the machine.

To replace…Pull the two catches on theunderside of the plateoutwards to release them.Slide the plate into itslocation guides and release the catches to lock the plate inposition.

Reference

6-3

Removal & Replacement of the Insert Tray

To remove…Open the top cover. Pull theinsert tray straight outwardsfrom the machine.

To replace…Slide the tray into its locationguides and push until it‘clicks’ into place.

Access to Carriage AssemblyThe carriage assembly canbe pulled outwards to gainaccess. The insert feederand Fold Plate 2 must beremoved first.

Access to Envelope Feeder Area

To gain access…Pull the release lever in thedirection of the arrow.

Lift the envelope area feedrollers to gain access.

To relatch feed rollers…Release the envelope areafeed rollers and let them restin position.

Push the rollers firmly down until they latch into position.

Note: Access to this area can be improved by removing Fold Plate1 and sheet feeder 2.

Reference

Reference

6-4

Access to the Envelope Exit Area

Pull down the access door asshown to gain access tojammed material.

When closing the accessdoor, make sure it is firmlylatched into position.

Access to the Envelope Inserting Area

Access can also be gained tothe insertion area by liftingthe tinted plastic cover.

Access to the Sheet Feed Area

To gain access…Open the top cover.

Squeeze the two blue handles together and pivot the guideassembly to the right to gainaccess.

To relatch…Squeeze the two bluehandles together and pivotthe guide assembly back toits closed position. Releasethe two blue handles makingsure the assembly issecurely latched intoposition.

Close the top cover.

Reference

6-5

MACHINE

Blank ScreenNo Display

Machine willnot operate

ENVELOPES

Envelopes failto feed

a) No Power

b) Machine notswitched on

a) Cover open

b) Feed trays/foldtrays not incorrectly

a) Envelope sideguides too tight

b) Poor envelopequality

a) Check power cord isfirmly connected ateach end, and the wallsocket is switched ON.

b) Switch machine on.Switch located on leftside of machine.

a) Check that all coversare closed - checkdisplay for coverlocation.

b) Remove and relocateall feeder and fold traysfirmly.

a) Adjust width ofenvelope side guides.Adjust the side guidesup to envelopes thenback-off setting knobhalf a turn.

b) Check envelopes arenot curled. If excessivetry a new batch/box.Make sure the

2-1

2-1

6-2

6-2

2-5

2-5

SYMPTOM POSSIBLE REMEDY PAGECAUSE REF.

Troubleshooting

Reference

6-6


ENVELOPES(Continued)

Envelopes failto feed (cont.)

More than oneenvelopefeeds

Envelopefailedto open

c) Envelope guidestoo loose

d) Wedge setincorrectly

e) Envelopesincorrectlyloaded.

a) Poor envelopequality

b) Envelopesincorrectlyloaded.

a) Envelopesincorrectlyloaded

envelopes have beenfanned and aeratedbefore loading.

c) Adjust width ofenvelope side guides.Adjust the side guidesup to envelopes thenback-off setting knobhalf a turn.

d) Position wedge tosupport envelope stack.

e) The lead edge of thefirst envelope should beunder the front feedrollers.

a) Check envelopes arenot curled, if excessivetry a new box/batch.Make sure theenvelopes have beenfanned and aeratedbefore loading.

b) The lead edge of thefirst envelope should beunder the front feedrollers.

a) Load envelopes on feeddeck with flaps up andtrailing.

2-5

2-5

2-5

2-5

2-5

2-5

Reference

6-7


ENVELOPES(Continued)

Envelopefailedto open(continued)

Envelopes notsealing

b) Poor envelopequality

c) Envelope feedunit not latcheddown correctly

a) No water

b) Seal mode notselected

a) Feeder notselected to feed

b) Side guides tootight

Make sure theenvelopes are loaded infeeder squarely.

b) Check envelopes arenot stuck due to beingdamp. If excessive try anew batch/box.

c) Check envelope jamaccess area, is latcheddown firmly, located atthe envelope feedingarea.

a) Remove water bottleand fill up to indicatedlevel, replace bottle.Bottle is located on rightside of machine at rear.

b) Check job set up.Activate seal mode.

a) Check job set up

b) Adjust width of materialside guides.Adjust the side guidesup to material thenback-off setting knob aquarter turn.

2-5

6-3

2-8

25

5-7,5-9

2-3

SHEET FEEDER

Sheets fail tofeed

Reference

6-8


SHEET FEEDER(Continued)

c) Paper notloadedcorrectly

a) Daily mail(manual feedmode) isselected

b) Paper notloadedcorrectly

a) Insert guidestoo tight

b) Feeder notselected tofeed

c) Poorseparation

d) Side guidestoo loose

e) Wedge setincorrectly

c) Aerate the stack ofpaper, making surethat individual sheetsare not stuck together.

a) Check job set up andmanual feed lever.

b) Aerate the stack ofpaper, making surethat they are not stucktogether.

a) Adjust width ofmaterial side guides.Adjust the side guidesup to material thenback-off setting knob aquarter turn.

b) Check job set up.

c) Check Lever setting iscorrect.Check stone shield isin correct position.

d) Adjust side guides.

e) Rest wedge behindmaterial to support it.

2-3

2-2

2-3

2-6

5-7,5-9

5-9

2-4

2-5

More than onesheet is fed

INSERT FEEDER

Inserts fail tofeed

Reference

6-9


INSERT FEEDER

More than oneinsert is fed

Failure toinsert

a) Poor separation

a) Wrong envelope

b) Side guides setup

c) Poor fold

d) Poor qualityenvelope

a) Check Lever setting iscorrect. Check stoneshield is in correctposition. Reduce leversetting by 1.

a) Check that you areusing the correctenvelope for the jobselected. If problemsstill occur changeenvelope stop position.

b) Check ALL feeder sideguides, are not set toowide.

c) Check the fold selected,in job set up is thecorrect one for thematerial length you areusing.

d) Check window ofenvelopes are not stuckdown due to excessiveglue. Try a new batch/box.

2-6

5-12

2-3 to2-8

5-6

(Continued)

Reference

6-10

Error Recovery for Empty Feeders

Error Recovery for Normal Job (non-OMR)

SYMPTOM POSSIBLE REMEDY PAGE CAUSE REF.

Error Recovery for OMR Job

If the machinestops duringan OMR Job

a) OMR Errormessage(as listed onpage 6-15)

a) Press the Clear Deck key.The envelope at theinsertion area will eject intothe stacker. The remainingpages of the current set willfeed/fold and eject into thestacker, and can bemanually inserted into theenvelope. The FIRST pageof the NEXT set will prefeedinto the feed rollers andstop. Press Start tocontinue.

1-7

If the machinestops during anaccumulationof a job (non-OMR)

a) Too manysheets or ajam

a) Press the Clear Deck key.The envelope at theinsertion area will ejectinto the stacker.MANUALLY remove theremaining pages of the setfrom the appropriatefeeder and fold/insert intothe envelope. Once thecause of the stoppage hasbeen determined, pressStart to continue.

1-7

If feeder runsout of materialand stops

a) Ran out ofmaterial

a) Press Stop (and thenClear Deck if material isin transit), re-fill emptytray, and press Start tocontinue.

1-7

Reference

6-11

Error Messages - Paper Handling

MESSAGE ACTION

CALL SERVICE Power machine off and on. Ifmessage is still displayed Callservice.

CHECK /CLEAR FEEDER Feeder indicated has failed tofeed material. Removematerial from the feed tray,reload and restart machine.

CHECK FEEDER Feeder indicated is not locatedcorrectly. Remove tray andrelocate.

CHECK FOLD PLATE Fold plate indicated is notlocated correctly. Remove FoldPlate and relocate.

CHECK INVERTER Envelope inverter unit has notset to it’s correct position.Open inverter cover and checkfor any material. Close coverand restart.

CHECK LAST MAIL PIECE Envelope has failed to open.Check envelopes are loadedcorrectly. Reload envelopes andrestart machine.

CLEAR FOLD PLATE Material has been detectedinside the Fold Plate indicatedon the display. Remove FoldPlate and check for anymaterial. Replace Fold Plate.

CLEAR INSERTION AREA Material has been detected inthe inserting area. Open tintedplastic cover on right hand sideof machine and remove anymaterial. Close cover andrestart.

Reference

6-12

MESSAGE ACTION

CLEAR MOISTENER Material has been detected inthe sealer brush area. Opentinted plastic cover on righthand side of machine andremove any material. Closecover and restart.

CLEAR SEALER Material has been detected inthe sealer brush area. Opentinted plastic cover on righthand side of machine andremove any material. Closecover and restart.

CLOSE COVER Cover indicated is not fullyclosed. Close indicated coverand restart.

CLOSE HAND CRANK The hand crank door not fullyDOOR closed. Close cover located at

front left of machine.

DEFLECTOR ERROR The function of half fold is notpossible due to a fault. RemoveFold Plates and check for anymaterial.

DOUBLE FEED A double feed has beendetected being fed from thefeed tray indicated. Remove thematerial from the machine andrestart. If double feeds persist,request another trial piece.

DOUBLE FEED CHECK A double feed has beenSTACKER detected being fed from the

feed tray indicated. Removethe double feed from thestacker. Restart machine.

Reference

6-13

FOLD PLATES NOT SET The Fold Plates has not set tothe correct position. RemoveFold Plates and check for anymaterial. Replace Fold Platesand restart.

MANUAL FEED TIMEOUT Material has not been detectedbeing fed from the feeder. Inmanual feed mode, the materialmust be fed by a set time.Restart the machine by pressingStart.

PAPER SHORT The material being used hasbeen detected to be too short inlength. Check material lengthbeing used matches the lengthdisplayed. If correct, requestanother trial piece.

PAPER SHORT CHECK The material being used hasSTACKER been detected to be too short

in length. Check materiallength being used matchesthe length displayed. Ifcorrect, request another trialpiece.

SET LEVER Manual feed lever in theincorrect position for the modeof running. Move the manualfeed lever to the correctposition. (Left position:manual,Right:auto).

STREAM FEED The machine has detected twosheets being fed together fromthe feed tray indicated. Removematerial from the machine,reload and restart machine.

MESSAGE ACTION

Reference

6-14

MESSAGE ACTION

STREAM FEED CHECK The machine has detectedSTACKER two sheets being fed together

from the feed tray indicated.Remove the stream feed fromthe stacker. Reload machineand restart.

SYSTEM ERROR POWER A fault has been detected inDOWN the main software. Switch

machine off and on and retry.If problem persists, callservice.

TRAY EMPTY Tray indicated has no material.Reload tray and press Start.

Reference

6-15

Error Messages - OMR

MESSAGE ACTION

BAD OMR MARKSSPACING

Two marks detected that are closertogether than half the expecteddistance.

NO OMR MARKS No marks on paper.

Sensor not centered over marks onpaper.

Paper not face-up, top-first forC/double fold, or not face-down,bottom first for Z/single fold.

BAD OMR CODE LENGTH Code misread by sensor.

Code type on paper does not matchOMR menu in user setup (e.g. paperhas selective feed and sequencemarks but setup does not specifyOMR + Sequence + Sel-Insert.

BAD OMR CODE FORMAT Code misread by sensor.

Code does not have the fixed marksin the right places (benchmark, safetyand re-timing).

EXPECTED 1ST SHEETOF SET

Code misread by sensor.

A new envelope is required but thesheet is not the last of a set (i.e. theNot-BOC mark at code position 4 ispresent).

NOT A NEW ENVELOPE, Code misread by sensor.

An envelope is at the Q-station butthe sheet is the first of a set (i.e. theNot-BOC mark at code position 4 isabsent).

OMR:PARITY ERROR Code misread by sensor.

The code does not have an evennumber of marks

OMR:WAS ERROR Code misread by sensor.

The sequence number is notsequential to that of the previoussheet.

Reference

6-16

OMR:SF MARKSINCONSISTENT


The selective feed and autobatchmarks at code positions 7 to 9 aredifferent to those on the previoussheet for this set.

OMR:SF NOT IN USE Code misread by sensor.

A selective feed mark at codepositions 7 to 8 is present but the jobsetup does not define the feeder asSF.

OMR:COLLATION TOOLARGE


The set contains more than 5 sheetsfrom the main feeder.

OMR:END OF BATCH This is not normally an error. TheAutoBatch mark is present on this set,causing the machine to stop.

MESSAGE ACTION

Suggestions for Repeated OMR Errors

The following suggestions may help you lead to a solution for repeatedOMR errors:

1. Have you cleaned off the OMR scanner of accumulated dust?

Lightly dust off the scanners with a non-abrasive cloth. See page 4-3for location of scanners.

2. Is the OMR scanner aligned over the OMR marks on your documents?

Refer to pages 5-14 to 5-16 for proper positioning of the scanner.

3. Do the OMR marks on your documents meet the proper specifica-tions for spacing, size, and location?

Refer to pages 4-25 and 4-26 or the OMR Template/Guidelinessupplement (SV40193) to verify that you have printed the OMR markscorrectly.

If none of these suggestions help, please call Pitney Bowes Service.

Reference

6-17

Material Specifications

Sheet FeedersMin sheet size: 5" (127mm) Width 5" (127mm) LengthMax sheet size: 9" (229mm) Width 16" (406mm) LengthPaper weights: 16 lb (60g/m2) Min 32 lb (120g/m2 ) Max

Fold configurations : Material length limits before foldingSingle fold: 5" - 12 2/5" (127mm - 315mm)“C” - Letter fold: 5 9/10" - 14" (150mm - 356mm)“Z” - Accordion fold: 7 9/10" - 14" (201mm - 356mm)Double fold: 12" - 16" (305mm - 406mm)Double Document Detector Material range: 16 lb (60g/m2) Min

(32 lb (120g/m2) MaxFeed tray capacity: Up to a max of 100 sheets of 20 lb (80g/m2)

Daily Mail(Hand feed) mode:

Stapled sets up to 5 sheets of 20 lb (80g/m2) toa maximum total weight of 120 lb (400g/m2)per set can be processed in the Daily Mailmode. Only Sheet Feeder 1 (plus the InsertFeeder if required), can be used for DailyMail applications. The maximum compressedthickness after folding should not exceed0.078" (2mm). Glossy/coated sheets are notrecommended.

Insert FeederMin Insert size: 5" (127mm) Width 31/4" (82mm) LengthMax Insert size: 9" (230mm) Width 6" (152mm) Length

Paper Weights: 20 lb (75g/m2) Min 48 lb (180g/m2) Max(Non folded cut sheet) (Single Sheet)16 lb (60g/m2) Min(Folded Material)

And Inserts of up to a maximum compressedthickness of 0.078" (2mm).

Pre-folded or single panel inserts should be fed from Insert Feeder.

Double Document Detector Material range: 16 lb (60g/m2) Min32 lb (120g/m2) Max

Feed tray capacity: Up to a maximum of 100Inserts

Reference

6-18

Sealer The machine can seal up to a maximum of 1200 envelopesbetween refills.

Stacker The envelope stacker can accommodate up to 150 filledenvelopes. (Dependent on size and contents of theenvelope.)

Envelope Feeder

Min envelope size: 3 1/2" (88mm) Depth 8 3/4" (220mm) WidthMax envelope size: 6 3/8" (164mm) Depth 9 1/2" (242mm) WidthEnvelope weights: 17 lb (65g/m2) Min 26 lb (100g/m2) Max

Envelope tray capacity: Up to a maximum of 100 envelopes

End Clearance: End clearance between the Insert and enve-lope is a minimum of 1/4" (6mm) at each sidei.e. a minimum of 1/2" (12mm) overall. Thismeasurement should be taken with all docu-ments placed into the envelope.

Depth Clearance: The Insert must allow a minimum clearance of1/8" (3mm) for unfolded documents, and 1/4"(6mm) for folded documents, below the flapcrease after it is fully inserted into the enve-lope.

Envelope flap andthroat requirements: See illustration below.

WIDTH

DE

PT

H

Min. 1" (25.5mm)

3/4" (19mm)

Max. 2-1/2" (63mm)

Min. 1/4" (6mm)Max. 1-3/4" (44mm)

Min. 1/16" (1.6mm)

Closed flap tip shouldnot come closer than

1-3/4" (44mm) to bottomof envelope

Max. 1/4" (6mm)throat depth at3/4" (19mm) in fromedge of envelope

Reference

6-19

Material RequirementsFor best performance, use only materials approved by PitneyBowes.

Materials should be good quality and properly stored.

Recommended storage conditions: 65°F (18°C) to 77°F (25°C)40% to 60% relative humidity

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUTNOTIFICATION AND ARE SUBJECT TO TEST

OMR Specifications (General)

Mark Dimensions (see also OMR Template SV40193-TM)Width: min. 10mmThickness (height): 0.35mm - 0.70mm (1-2 point size)Space between marks: min. 3mmSpace on sides of marks: min. 2mm white space

ScannersUpper Scanner on Sheet Feeder 1 - supports:

• C-Fold documents• Double Fold documents

Lower Scanner on Sheet Feeder 2 - supports:• Z-Fold documents• Single (half) Fold documents

OMR Levels (see also Chapter 4 -What Is OMR?)Basic Level Features (OMR Group 1):

• EOC (end-of-collation)• BOC (beginning-of-collation)

Enhanced Level Features (OMR Groups 1, 2, and 3):• EOC (end-of-collation)• BOC (beginning-of-collation)• SF1 (feed from other sheet feeder)• SF2 (feed from insert feeder 2)• Auto-Batch (stop job after processing this document set)• WAS (wrap-around sequence, for numeric tracking of each sheet)

Reference

6-20

Machine Specifications

Physical Dimensions:Length 36" (915mm)Depth 20" (510mm)Height 24" (610mm)Weight 121 lbs (55kg)

Noise LevelRunning < 74dBA

ElectricalU.S.A.: 110V, 60Hz, 6AEurope: 230V, 50Hz, 3A

Speed:Up to a maximum of 2500 cycles per hour (depending on fold typeand material quality)

Fold ModesSingle fold“C” - Letter fold“Z” - Accordion foldDouble fold

ComplianceUL Listed

Reference

6-21

Usage

Pitney Bowes has tested this machine under manydifferent conditions and recommends that you do notexceed the usage levels specified below.

DI350 ModelMonthly ............. 20,000 cycles maximumYearly ................ 240,000 cycles maximum

Usage beyond these recommended cycles is not coveredunder your Equipment Maintenance Agreement.

Machine LifeFive Years

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUTNOTIFICATION AND ARE SUBJECT TO TEST

ServiceShould you have questions about your DI350 inserter, orrequire service or assistance with your particular application,please call your Pitney Bowes district office. The phone numberwill be on a sticker on your machine. A Pitney BowesEquipment Maintenance Agreement is available to keep yourmachine in top condition at nominal cost.

Reference

6-22

Appendix A –Training Checklist

A-1

Use the enclosed checklist when learning how to use your DI350inserter.

Introduction (Chapter 1)

1. ____ Features of the machine pp. 1-5, 1- 62. ____ Safety pg. 1-73. ____ Machine identification pp. 1-8, 1-94. ____ Control panel pp. 1-10 to 1-12

Operation (Chapter 2)

1. ____ Connecting power pg. 2-12. ____ Selecting and running a job pg. 2-13. ____ Running a trial piece pg. 2-24. ____ Starting the machine operation pg. 2-35. ____ Setup of the sheet feeders pg. 2-36. ____ Setup of the envelope feeder pg. 2-47. ____ Setup of the insert feeder pg. 2-58. ____ Filling the sealer pg. 2-69. ____ Programming options by model pg. 2-7

Create (Program) Non-OMR Job (Chapter 3)

1. ____ Creating a new non-OMR job pp. 3-1 to 3-142. ____ Changing an existing job pg. 3-153. ____ Deleting a job pg. 3-15

Appendix A –Training Checklist

A-2

What Is OMR? (Chapter 4)

1. ____ What is OMR? pg. 4-12. ____ What do OMR marks look like? pg. 4-23. ____ How are OMR marks read? pg. 4-34. ____ Considerations when using OMR pg. 4-20

Create (Program) OMR Job (Chapter 5)

1. ____ Creating a new OMR job pp. 5-1 to 5-172. ____ Changing an existing job pg. 5-183. ____ Deleting a job pg. 5-18

Reference (Chapter 6)

1. ____ Changing the display language pg. 6-12. ____ Clearing material pp. 6-1 to 6-44. ____ Trouble shooting pp. 6-5 to 6-105. ____ Error messages pp. 6-11 to 6-166. ____ Material specifications pp. 6-17 to 6-197. ____ OMR specifications pg. 6-198. ____ Machine specifications pp. 6-20, 6-219. ____ Service pg. 6-21

Index

I–i

AAccumulation Mode 3-5Accordion (“Z”) Fold 1-8, 2-9, 3-5, 3-14, 4-25, 5-6, 5-17, 6-17Auto-Batch Marks 4-7, 4-15, 4-26

BBatch Mode 3-13, 5-13Beginning of Collation (BOC). See Not Beginning of Collation (Not BOC).Benchmark (BM) 4-6, 4-10, 4-12, 4-26

C“C” Letter Fold 1-8, 2-9, 3-5, 3-14, 5-6, 5-17Changing Display Language 6-1Choosing New Job Number 3-2, 5-2Clearing Material From Machine. See Jam Access in MachineConfirming Job Setup 3-13, 5-13Connecting Power 2-1Control Panel 1-10

DDescriptions, Model

One-Station Model 1-6Three-Station Model 1-5Two-Station Model 1-6

Display Language, Changing 6-1Display Symbols 1-12Double Fold 1-8, 2-9, 3-5, 3-14, 4-25, 5-6, 5-17, 6-17Double Detect (non-OMR) 3-7, 3-8, 3-9Double Detect (OMR) 5-7, 5-8, 5-9

EEnd of Collation (EOC). See Not End of Collation (Not EOC).Envelope Depth Dimension 3-12, 5-12Envelope Feeder

Access for Jam Clearing 6-3Description 1-4, 1-5Insertion Mode 3-9Job Setup 3-8, 5-8Mechanical Setup 2-5Specifications of Envelopes 6-18Troubleshooting 6-5, 6-11

Envelope Stop Dimension 3-12, 5-12

Index

I –ii

ErrorsEnvelope Feeder 6-5Insert Feeder 6-8OMR 6-10, 6-15Paper Handling 6-11Sheet Feeders 6-7

FFeeders, Mechanical Setup

Envelope Feeder 2-4Filling the Sealer 2-6Insert Feeder 2-5Sheet Feeders 2-3

Feeders, Settings for OMR JobEnvelope Feeder 5-8Main (Scanning) Sheet Feeder 5-7Other Sheet Feeder 5-7Insert Feeder 5-9

Feeders, Settings for Non-OMR JobSheet Feeder 1 3-7Sheet Feeder 2 3-8Envelope Feeder 3-8Insert Feeder 3-9

Flowchart, Non-OMR Job 3-3Flowchart, OMR Job 5-4Fold Type

Setting 3-6, 5-6Adjustments When Testing 3-14, 5-17

Fold A and B Dimensions 3-11, 5-11Fold Only vs. Insertion Mode 3-9

HHalf (Single) Fold 1-8, 2-9, 3-5, 3-14, 4-25, 5-6, 5-17, 6-17

IInsert Feeder

Access for Jam Clearing 6-4Description 1-4, 1-5Insertion Mode 3-9Job Setup 3-9, 5-9Mechanical Setup 2-6Specifications, Material 6-17Troubleshooting 6-8, 6-11

Index

I–iii

Insertion Mode 3-9

JJam Access in Machine

Carriage Assembly 6-3Clearing Material 6-1Hand Crank 6-1Envelope Exit Area 6-4Envelope Feeder Area 6-3Envelope Inserting Area 6-4Fold Plates 6-2Insert Tray 6-3Removal/Replacement of Sheet Feeder and Envelope Trays 6-2Sheet Feed Area 6-5

Jobs, Non-OMRChanging Existing Job 3-15Confirming Job Setup 3-13Deleting Job 3-15Entering New Job (Programming) 3-1Flowchart for Non-OMR Job 3-3Selecting Non-OMR Option 3-2Selecting and Running Job 2-1Testing Job 3-14

Jobs, OMRAdjustment of OMR Scanner 5-14Changing Existing Job 5-19Confirming Job Setup 5-13Deleting Job 5-19Entering New Job (Programming) 5-1Flowchart for OMR Job 5-4Loading Material 5-17Selecting and Running Job 2-1Selecting OMR Option 5-3Testing Job 5-18

MMachine Identification 1-8Manual Feed 1-8, 2-2, 3-7, 6-13Mechanical Setup, Feeders. See Feeders, Mechanical Setup.Models, Descriptions

One-Station 1-6Three-Station 1-5Two-Station 1-6

Index

I –iv

Models, Programming Options 2-7

NNot Beginning of Collation (Not BOC) 4-6, 4-11, 4-12, 4-26Not End of Collation (Not EOC) 4-6, 4-10, 4-12, 4-26

OOMR (Optical Mark Recognition)

Considerations When Implementing 4-20Errors 6-10, 6-15Explanation of 4-1, 5-1Generation (Creation) of 4-4Group Combinations 4-9Group 1 (“OMR”) 4-10Group 2 (“Select Feed”) 4-14Group 3 (“Sequence”) 4-17How They Look 4-2Jobs, Entering 5-1Marks Used with DI350 4-5Reading of 4-3Specifications 6-19Template, OMR 2-26Troubleshooting 6-10, 6-15

PPaper Length Dimensions 3-10, 5-10Parity 4-6, 4-11, 4-12, 4-26Programming (Entering) Jobs

Non-OMR Job 3-1OMR Job 5-1

Programming Options by Model 2-7

RRetime Marks 4-6, 4-10, 4-12, 4-26

SSafety (OMR mark) 4-12, 4-15, 4-17, 4-26Safety Procedures 1-7

Index

I–v

Scanner, OMRAdjustment of 5-1Descriptions of (upper and lower) 1-4, 1-6, 4-3, 5-14Errors When Scanning 6-15Placement of Paper Under, 4-22, 4-24

Sealer 3-10, 5-10, 6-18Select Feed Marks (SF1 and SF2) 4-7, 4-15, 4-26, 5-8, 5-9Setup, Mechanical

Envelope Feeder 2-4Filling the Sealer 2-6Insert Feeder 2-5Sheet Feeders 2-3

Setup, Job. See Jobs, Entering New Job.Setup Mode 3-1, 5-1Sheet Feeders (1 and 2)

Access for Jam Clearing 6-4Description 1-4Job Setup 3-7, 3-8, 5-7, 5-8Mechanical Setup 2-3Specifications, Material 6-17Troubleshooting 6-7, 6-11

Single (Half) Fold 1-8, 2-9, 3-5, 3-14, 4-25, 5-6, 5-17, 6-17Specifications

Compliance 6-20Electrical/BTU Rating 6-20Fold Modes 6-20Machine Life 6-21Material Requirements 6-19Material Specifications 6-17

Sheet Feeders 6-17Insert Feeder 6-17Sealer 6-18Stacker 6-18Envelope Feeder 6-18

Noise Level 6-20Physical Dimensions 6-20Speed 6-20Usage 6-21

Stacker 1-5, 3-10, 5-10, 6-18Start Machine 2-3

Index

I –vi

TTemplate, OMR 2-26Training Checklist, Operator A-1Trial Piece 2-2Troubleshooting

Envelope Feeder 6-5Insert Feeder 6-8OMR (Optical Mark Recognition) 6-10, 6-15, 6-16Paper Handling 6-11Sheet Feeders 6-7

WWrap-Around-Sequence (WAS) Marks 4-8, 4-17, 4-18, 4-26, 5-3

Z“Z” (Accordion) Fold 1-8, 2-9, 3-5, 3-14, 4-25, 5-6, 5-17, 6-17